Przebieg r20261030-0409-v000-zadymiarka-concept-2

ZAD-1 compact fog machine: requirements designed to (concept tier)

Source of the customer requirements: INPUT/requirements.md (ids kept exactly). This document adds three things for each requirement: the concept design-to value, the verification method, and the planned test that the prototype test plan must contain. It also lists the derived requirements (DRV-xx) that flow down to the sub-systems, and the use conditions.

Legend. Method: A analysis/calculation, I inspection (CAD, BOM, documents), D demonstration, T test. Status words used here and in compliance.csv: met / partly / not_met / not_addressed (defined in compliance.csv notes and in ../REPORT.md §5). Planned tests T-01..T-30 are all NOT RUN: no hardware exists at concept tier. Evidence paths are relative to deliverables/.

0. Use conditions (ASSUMPTION unless stated)

• Operation 5-40 °C ambient (ZAD-REL-02), storage −20 to +60 °C, indoor, non-condensing, ≤ 2000 m.
• Mains: EU 220-240 V~ 50/60 Hz (tested 207-253 V); US 120 V~ 60 Hz (tested 108-132 V).
• Fluids: water-based glycol fog fluids to ANSI E1.5 (quick-dissipating, standard, long-hang). The rating fluid STD is 70 % water, 25 % propylene glycol, 5 % triethylene glycol (ASSUMPTION, 02-concept/key-estimates.md §1).
• Users: non-specialists and lighting desks; the unit stands on the floor or hangs from a truss (bracket and safety cable); it is used near people, microphones and smoke detectors.

1. Customer requirements with design-to values and verification

2. Derived requirements (flow-down to sub-systems)

3. End-of-line test limits (ZAD-MFG-03, concept values, ASSUMPTION)

ZAD-1 compact fog machine: system architecture (concept B)

Block diagram: block-diagram.svg (PNG copy block-diagram.png, source block_diagram.py). Numbers are labelled; calculated values come from estimates/concept_estimates.results.json (CALCULATION / SIMULATION) unless noted. Concept tier: no CAD, schematic or firmware exists yet.

1. Product in one paragraph

ZAD-1 is a 1000 W, ≈ 2.7 kg, 300 × 170 × 185 mm fog machine for ANSI E1.5 water-glycol fluids. A 0.5 kg cast aluminium exchanger with a cast-in stainless coil and a 980 W heater reaches READY in ≈ 2.8 min. A silent stepper peristaltic pump meters 0.5-60 ml/min. The firmware matches pump flow to the heat the exchanger can deliver, so output never stops for reheating: at 100 % it derates smoothly to ≈ 23.5 ml/min continuous (standard fluid, 230 V). The unit can be controlled from DMX512-A with RDM (5-pin and 3-pin XLR in and thru, isolated), from the included two-way 2.4 GHz remote (up to 4 machines, status LEDs), or from its own OLED/encoder panel with a built-in timer. It needs no app, account or internet connection. It is a Class I appliance in an earthed, powder-coated aluminium housing. Overheat protection is electromechanical and does not depend on firmware. Two mains variants exist: EU 220-240 V and US 120 V.

2. Physical layout (concept envelope, ASSUMPTION until CAD)

 side view, x -> front (nozzle)                     top: wide-mouth fill cap at x~90, folding handle x 20-120
 z (mm)
 185 .   ___handle___
 165 +--------------------------------------------------------------+
     | PSU   main PCB      ||  .----- insulated exchanger -----.   |
     | UI board on the     ||  | Al block + coil + heater,     |===| nozzle 4 mm + perforated guard -> fog
 100 | rear panel: OLED,   ||  | 250-290 C, stainless shroud   |   |
     | encoder, XLR x4,    ||  '-------------------------------'   |
     | IEC inlet, USB-C    ||    peristaltic pump (soft mounts)    |
  60 | .---- tank 1.45 L, lit level window ----.  heat shield ||   |
  12 | '---------------------------------------'                   |
   0 +--feet---------------------------------------------feet-----+
     0                                   170                    300 mm

• Envelope including feet and folded handle: 300 × 170 × 185 mm = 9.4 L (ZAD-SIZ-01 target ≤ 12 L, ZAD-SIZ-02 target ≤ 320 mm). The bracket, cord and remote are excluded.
• Cold rear zone: tank, electronics, user interface, connectors, handle. Hot front zone: exchanger and nozzle. A stainless heat shield separates them. The handle and controls are ≥ 150 mm from the outlet (ZAD-SAF-03).
• Tank at the bottom rear, the lowest point of the fluid path, so gravity never feeds the coil (ZAD-PRF-07). Wide-mouth cap on top at the rear, far from the nozzle, for hot refill without tools (ZAD-UX-03). An RGB LED lights the translucent level window, which is visible from 3 m.
• Centre of mass (CALCULATION): empty (157, −1, 89) mm, full (133, 0, 74) mm. The minimum tip angle is 38° empty and 43° full (ZAD-SAF-04 target ≥ 20°).
• Hanging bracket: a U-yoke on the side walls with knob screws and tilt steps of 15°, a Ø 13 mm clamp hole and a safety-cable eyelet (ZAD-FUN-08).

3. Fluid path and anti-spit measures (ZAD-PRF-07, ZAD-FUN-06, ZAD-FUN-08, ZAD-SAF-05)

Tank (1.45 L, 1.28 L usable) → weighted flexible pick-up with 100 µm filter, reachable through the cap without tools → capacitive low-level sensor (stop with 100 ml left) → stepper peristaltic pump (3.2 mm tube, 0.41 ml/rev) → relief valve 3 bar (returns to the tank) → 316L coil cast into the block → 4 mm nozzle, thermally coupled to the block → perforated stainless guard.

Hydraulics (CALCULATION): back-pressure ≈ 0.13 bar at the continuous rate and ≈ 0.71 bar at 60 ml/min, below the ≈ 2 bar capability of the pump (ASSUMPTION, to be confirmed from pump data). Nozzle exit velocity ≈ 58 m/s continuous, so jet noise ≈ 27 dB(A) at 1 m.

4. Thermal design

5. Control strategy (firmware, ZAD-PRF-03, -05, -06, ZAD-SAF-07)

States: OFF (mains switch, 0 W) → STANDBY (heater relay open, radio and DMX listening, ≈ 0.25 W) → HEATING (progress shown as %) → READY (T ≥ setpoint − 5 K) ⇄ FOGGING → DERATED (output below command because of the heat limit; shown on display, remote and RDM) → FAULT (relay open, pump stopped, code shown). Further states: CLEAN (guided purge) and AUTO-OFF (idle timer back to STANDBY; off / 15 / 30 / 60 / 120 min, default 60).

Heat-balance flow control (implemented in the lumped model run_100pct() of concept_estimates.py):

q_ff    = (P_heater_est(V_rms) - P_loss_est(T)) / e_fluid          feed-forward from measured mains voltage,
                                                                   EOL-calibrated heater resistance, loss map
q_allow = q_ff + Kp * (T - T_floor),   T_floor = T_min + 5 K        feedback on block temperature
q_pump  = clip(min(q_command, q_allow), 0, 60 ml/min);  q_pump = 0 if T < T_min (interlock)
heater  = 100 % while fogging below setpoint, PID otherwise

Results (SIMULATION, STD fluid): after a 100 % command from first READY, 19.7 ml is vaporised in the first 30 s. The output then settles at 23.6 ml/min (230 V) or 19.0 ml/min (207 V). The longest pause is 0 s in every case, including a 10 % error in the fluid energy (21.5 and 17.3 ml/min, with the block ≥ 234 °C). The firmware also runs a flow observer, q_obs = (P_heater·duty − P_loss − C·dT/dt) / e_fluid. It corrects tube slip and wear (ZAD-PRF-06), and detects air, pump failure or a blocked outlet as a difference between commanded and absorbed flow.

Other rules: no pumping unless READY (ZAD-SAF-07). On DMX loss (no valid frame for 1.0 s) output stops, unless the user selected hold (ZAD-SAF-07 target ≤ 2 s). Continuous mode started from the remote auto-stops after 10 min (adjustable). When the low-level sensor trips, the pump stops with 100 ml left, so no air enters. After refill, fogging resumes automatically with no priming (ZAD-FUN-06 target). The fluid-type setting (QD / STD / DENSE) selects the temperature window and e_fluid (ZAD-PRF-08).

6. Electrical architecture (ZAD-PWR-01, ZAD-SAF-06)

• Mains path: IEC C14 inlet with fuse and double-pole switch → EMI filter (X capacitor, common-mode choke, Y capacitors ≤ 1 nF to PE) → (a) heater path: thermal link → two manual-reset cut-outs (L and N) → 2-pole safety relay → zero-cross triac (insulated tab, on an internal aluminium spreader) → heater; (b) 24 V/20 W PSU module.
• Isolation: mains ↔ SELV is reinforced (PSU module, optotriac, relay coil-to-contact, creepage ≥ 8 mm at 250 V; ASSUMPTION to be checked against EN 60335-1 Table 17/18). SELV ↔ DMX has functional isolation (≥ 1.5 kV, digital isolator + isolated supply) against ground loops.
• Earthing: PE stud on the chassis; exchanger block, shroud, heat shield, all housing parts and the bracket are bonded ≤ 0.1 Ω (ZAD-SAF-06). Leakage budget 0.227 mA at 1.06 × 230 V (CALCULATION/ASSUMPTION: Y capacitor 0.077 mA + hot heater insulation 0.10 mA + PSU 0.05 mA).
• Currents (CALCULATION): EU 4.35 A rated, 5.0 A at 1.15 × input; US 8.33 A rated, 9.58 A at 1.15 × input (≤ 12 A, ZAD-PWR-02). Triac dissipation at full duty: 4.4 W (EU), 9.2 W (US).

7. Interfaces

DMX512-A (ANSI E1.11): 5-pin and 3-pin male IN plus female THRU, paralleled, with no internal termination (the user terminates the line). Start address 1-512 is set on the OLED; there are no DIP switches. Personalities:

RDM (ANSI E1.20): discovery, DEVICE_INFO, DMX_START_ADDRESS, DMX_PERSONALITY(_DESCRIPTION), IDENTIFY_DEVICE (display flashes, tank LED blinks), SENSOR_DEFINITION/SENSOR_VALUE (block temperature, fluid level state, mains voltage), STATUS_MESSAGES (heating, ready, derated, low fluid, fault codes), DEVICE_HOURS, SOFTWARE_VERSION_LABEL, plus manufacturer PIDs for fluid type, timer and auto-off.

Remote (2.4 GHz BLE Coded PHY, two-way): keys for momentary fog, continuous on/off, level +/−, timer start/stop, and machine select 1-4 / ALL (group). One bi-colour LED per machine shows green = READY, amber = heating, red = low fluid, red blinking = fault; a link LED shows the connection. Status is polled after every key press and for 10 s afterwards. The remote is factory-paired to its machine and can store 4 machines. Re-pairing: key combination on the remote and the PAIR menu on the unit within 30 s at ≤ 1 m. Frames use AES-CCM with a per-pair key and a 32-bit counter (replay protection), so neighbouring machines are never triggered (ZAD-FUN-03, -04). Link margin with BLE Coded PHY at 125 kbps (CALCULATION, datasheet sensitivity −104 dBm): 26.3 dB at 30 m, 21.8 dB at 50 m, 15.8 dB at 100 m. The antenna sits behind the polycarbonate display window, because the aluminium housing would block it (6 dB aperture loss assumed).

Unit UI (ZAD-FUN-07, ZAD-FUN-05): OLED shows warm-up %, READY, output %, DMX address and personality, timer (interval 1-600 s, duration 1-120 s, level 1-100 %), fluid type, auto-off, fault codes and hours. An encoder and 2 keys (FOG, MENU) operate it. Settings are stored in flash. USB-C service port (behind a cap): signed-firmware update, log and hours read-out (ZAD-SRV-03).

Diagnostics: fault codes E01 PT1000 open, E02 PT1000 short, E03 no temperature rise, E04 over-temperature (firmware), E05 hardware comparator/relay trip, E06 cut-out open, E07 pump/air (observer), E08 low fluid, E09 tilt, E10 mains out of range, E11 watchdog reset, E12 relay stuck, E13 blocked outlet suspected. Hours counters (power-on, heating, fogging, litres pumped) and a 32-entry fault log are kept in flash.

8. Mass budget (CALCULATION from ASSUMPTION part masses, estimates/concept_estimates.py §11)

9. Changes adopted after the safety and regulatory reviews

The safety FMEA (safety-concept-fmea.md, 49 failure modes) found five single faults without an adequate measure in the first baseline. The fixes below are adopted (cost line SAFE+ ≈ €2.5 per unit at 1,000, ASSUMPTION):

Regulatory decisions (from regulatory-route.md, manager disposition at its top):

• EU: RED 2014/53/EU only (LVD/EMC objectives via Art. 3(1)(a)/(b)), Module A, EN 60335-1 used alone plus a risk assessment, no protective electronic circuit and no software class B needed.
• US/Canada: FCC Part 15B SDoC; the machine uses the module grant FCC ID 2AC7Z-ESPC3MINI1. The handheld remote gets its own FCC ID change (the grant is mobile/fixed only). NRTL listing to UL 998 / CSA C22.2 No. 104 with the ANSI E1.29 fog-specific additions (fallback UL 499 / CSA C22.2 No. 64).
• DMX: 5-pin and 3-pin ports kept; E1.11 conformance claimed for the 5-pin ports and the interface, and the 3-pin ports declared as a deviation.

Benchmark, fog fluids and key purchasable components (concept-phase research note)

Run: r20261030-0409-v000-zadymiarka-concept-2 · Author role: research engineer · Date of all web reads and price reads: 2026-10-30 (unless a cell says otherwise) · Offline parts DB: lcsc info build 4325c9c05dd3280c, newest row 2026-10-29T11:52Z, age 0.65 d.

How to read this note

• Every number carries a label: SOURCE (document or page read; id [S#] points to the Sources list at the end, which holds the full URL; lcsc Cxxxx = offline LCSC/JLCPCB price DB, data age given), CALCULATION (shown, re-runnable) or ASSUMPTION (stated reason). n/a = not found; nothing was guessed.
• Prices are quoted in the currency of the page (USD, EUR, GBP, PLN ...). No FX conversion was done; the cost model must apply its own FX rate. LCSC/JLCPCB prices are USD list prices of the JLCPCB part catalogue; LCSC's own web ladder (read via wmsc.lcsc.com JSON for three parts) differs by < 1 %.
• "Search snippet" = the figure was seen in a web-search result summary and the page was not opened by me; it is marked as such and should be re-checked before it goes into a BOM.
• Hard rule kept: public web only, read-only; no company was contacted, no quote was requested, no account created.

0. Key findings in 12 points

1. Competitors' headline "fluid consumption" (30-150 ml/min) is a peak rate. Antari's own manual says continuous output without reheat pauses is only possible up to ~30 % volume on its 1.25-2.5 kW Z-1200/1500/3000 II machines; Look gives 35 ml/min continuous vs 120 ml/min max on the Viper NT (1300 W) [S7, S15].
2. Continuous rate per watt of the pro machines is 37-45 W per (ml/min) (Look Viper NT 37, Antari Z-1500 II 45, Z-3000 II 42; CALCULATION in 1.5). Our target (1000 W / 22 ml/min = 45.5 W per ml/min) is in the same band, but the energy balance (2.2-2.4 kJ/ml, CALCULATION in 2.2) says 22 ml/min needs about 830-880 W net, i.e. roughly 84-88 % of a 1000 W input must reach the fluid. There is almost no loss budget.
3. Only three machines in the set warm up in <= 3.5 min (Antari Z-800 745-800 W 2 min; BeamZ S700 700 W 3-3.5 min; Eurolite NSF-250 1000-1080 W 3 min). Heater energy during warm-up is 89-194 kJ for those vs 357-756 kJ for the 5-9 min machines (CALCULATION in 1.5), i.e. an exchanger of about 0.4-0.9 kg aluminium-equivalent vs 1.7-3.7 kg.
4. 1000 W-class DMX machines weigh 6.3-8.9 kg and cost USD 233-380 (street); our <= 3 kg / EUR 229 incl. VAT is a clear step below every DMX machine found.
5. Budget wireless remotes are weak (Eurolite NSF-250: 433.92 MHz, up to 5 m line of sight); no source read states two-way status or pairing IDs on a competitor remote.
6. Fluids: SDS data show three families - propylene glycol (+ glycerol) / water (Antari FLC 33 % PG, 65 % water; Antari FLG group 38-41 % PG, 6-8 % glycerol, 52-57 % water), PG + triethylene glycol (Martin/JEM, Le Maitre Global Deluxe, Rosco, Look) and diethylene glycol (Chauvet EU FFDJ5, <= 40 %). Energy per ml varies 1.7-2.4 kJ/ml across them (CALCULATION), density 1.01-1.12 g/ml. Older Antari SDS revisions name ethylene glycol - check SDS revision before approving a fluid.
7. No manufacturer publishes a per-fluid heat-exchanger temperature window. The only published figure is Antari's "average operating temperature 250 C" (Z-1000 III manual). A set-point window of 220-280 C with 250 C default is an ASSUMPTION (2.3).
8. Kamoer stepper peristaltic pumps (KPHM100-ST, KAS-ST, KFS, KCS) cover 5-65/88/135 ml/min with BPT tube life >= 1000 h and motor life 6000 h, but no maximum outlet pressure is published (all flow data are "without pressure"); 1-2 bar suitability is unverified and needs a bench test.
9. Vibratory pumps (ULKA EX5/EP5, 650 cc/min free flow, 15 bar, 48 W at 230 V / 41 W at 120 V, duty 2/1 or 1/1 min on/off) cost EUR 25-35 but need separate 230 V and 120 V versions and line-frequency-dependent metering.
10. Electronics: all core ICs are in the LCSC/JLCPCB DB with stock (IRM-30-24 USD 8.16 flat vs USD 11.40-12.90 at DigiKey; ESP32-C3-MINI-1-N4 USD 2.04 at 1000; TMC2209-LA-T USD 1.64 at 1000). Dual 3-pin + 5-pin Neutrik XLR in/thru alone is USD 9.78 at 1000 (CALCULATION), about 15 % of the EUR 60 unit-cost target (ASSUMPTION: about 1.1 USD per EUR). The listed electronics, XLR and a generic inlet sum to USD 32.91 at 1000 pcs (cost hot-spot note under the price table in 3.8).
11. Safety parts: a manual-reset cut-out at 300-330 C exists only as capillary limiters (E.G.O. 55.13452.010 AUD 91.94 qty 1; JUMO AED 1,764), bimetal manual-reset parts stop at 250 C; competitors use 190-215 C thermoswitches (Eurolite). Tf 240 C thermal links cost USD 0.53-0.87 (Cantherm SDF DF240S) but open at 240 C. Probes: sheathed PT1000 for >= 400 C costs EUR 38.50-77 at qty 1. No OEM price for a finished cast heat exchanger was found (spare blocks EUR 35-240; OEM die-cast block with stainless pipe USD 5-15 at MOQ 500).
12. Mains side: a Hongfa HF115F-I relay (16 A, 5 kV coil-contact, "reinforce insulation") is the right relay, not the plain HF115F listed in the DB; Finder 40.61 and Omron G2RL-1A-E also state reinforced insulation (8 mm). Schurter DD11 inlet with double-pole switch needs a separate fuse drawer (USD 15-22 total) vs USD 3.2-4.0 for a generic module with lower dielectric rating.

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1. Competitor benchmark

1.1 Selection

Ten machines, budget to pro, chosen because a manufacturer document or a live retailer page could be read today. Not tabulated because no primary or live source could be read: Martin/JEM ZR33 (discontinued; martin.com redirects to the JEM support page [S60]; only retailer figures: 1500 W, 7-8 min, 9.5 L, 19 kg, 1000 m3/min), Le Maitre, Rosco (V-Hazer is a haze machine: 900 W, 7-10 min initial heat-up, 0.9 L/h max [S38]), Showtec, Chauvet "Geyser", Cameo "Instant Fog 1200 Pro" (no such product found; the Cameo range found is Instant Fog 1700 Pro / 1700 T Pro and Phantom F5/H2), Antari "F-1".

1.2 Table 1A - electrical and performance as stated by the vendor

All cells SOURCE as cited in the last column unless tagged. "Volume figures" (cfm, m3/min) have no common test method; they are given only for completeness.

Additional Antari data used in 1.4 (SOURCE [S7], manual for Z-1200 II / Z-1500 II / Z-3000 II): Z-1500 II 1500 W, warm-up ~10 min, 110 ml/min, 6 L; Z-3000 II 2500 W, ~12 min, 200 ml/min, 6 L. Same manual: "When setting a fog output volume higher than 30 % for continuous operation, the fog machine occasionally needs to stop the fog output to reheat. When NON STOP BURST is selected, the fog machine adjusts the fog output volume and heater temperature automatically and does not need to stop the fog output to reheat."

1.3 Table 1B - physical, controls, street price

1.4 Source discrepancies found (do not mix these figures silently)

• Hurricane 1800 Flex: manual Rev. 3 [S3] says 5 min, 30 ml/min, 1,190 W, 8.9 kg; retailer page [S4] says 3 min, 80 ml/min, 1,560 W (12.9 A at 120 V), 8.7 kg. Likely a newer revision; the manual figures are used above.
• Antari Z-1000X MK3: 1000 W (bullet) vs 900 W (table) on one Thomann page [S8].
• ADJ Fog Fury Jett: 700/730 W (ADJ manual [S10]) vs 650/680 W (Thomann [S11]).
• Hurricane 1301: warm-up 5.5 min (spec list) vs "5 min" (text) on the same page [S1].
• Look Viper NT: weight 8.6 kg without canister (sheet [S15]) vs 17 kg incl. tank (manual [S16]); fog time at 100 % "approx. 30 s" (sheet) vs "approx. 40 s" in an older US manual (search snippet).
• BeamZ S700LED page: wired vs wireless remote, see M1 [S18].

1.5 Observations relevant to our targets

1. Stated ml/min is a peak, not a continuous rate. Antari: continuous without reheat only up to 30 % volume on the Z-1200/1500/3000 II; the "NON STOP BURST" mode derates volume and heater temperature automatically [S7]. Look Viper NT: 120 ml/min max, 35 ml/min continuous (29 %) [S15]. Cameo: 40 s at 100 %, then 60 s reheat, non-stop at 50 % [S14]. Antari DMX machines "can maintain maximum output for 30 seconds or more" [S6]. This is exactly the behaviour ZAD-PRF-03/-04 target; derating (not pausing) is only offered in Antari's higher-end firmware.
2. Watts per continuous ml/min (CALCULATION from the sources above): Look Viper NT 1300 W / 35 = 37.1; Antari Z-1500 II 1500 W / (0.30 x 110 = 33) = 45.5; Antari Z-3000 II 2500 W / (0.30 x 200 = 60) = 41.7 (assumes the 30 % volume threshold equals the continuous rate: ASSUMPTION); ours 1000 W / 22 = 45.5. Peak figures: 6.1 (ADJ Jett 730 W / 120), 9.6 (Hurricane 1301), 10.8 (Viper NT max), 12 (Cameo), 15.4 (Eurolite NSF-250), 16.7-17.9 (Antari Z-1000 X MK3 / II), 39.7 (Hurricane 1800 Flex manual: 1190 / 30), 57 (Antari Z-800 MK3: 745 / 13). The spread of 6 to 57 W per ml/min shows that the vendors do not use one method.
3. Compact class. Only the Antari Z-800 (3.5-4.2 kg, 745-800 W, 0.8 L, 13 ml/min, ~2 min, no DMX, USD 196) and BeamZ S700 (2.4 kg, 700 W, 3-3.5 min, EUR 56, no DMX) are below 4.5 kg. Our <= 3 kg target with 22 ml/min and DMX is +70 % stated output of the Antari Z-800 at lower weight.
4. Warm-up vs heater power (CALCULATION: stated W x stated warm-up, no losses, exchanger to 250 C, cp_Al = 0.90 kJ/kgK): Z-800 89 kJ -> 0.43 kg Al-equivalent; BeamZ S700 126 kJ (3 min) to 147 kJ (3.5 min) -> 0.61-0.71 kg; Eurolite NSF-250 194 kJ -> 0.94 kg; Antari Z-1000 360 kJ -> 1.74 kg; Hurricane 1800 Flex 357 kJ -> 1.72 kg; ADJ Jett 394 kJ -> 1.90 kg; Hurricane 1301 397 kJ -> 1.92 kg; Viper NT 546 kJ -> 2.64 kg; Cameo 756 kJ -> 3.65 kg. Target <= 3 min at 1000 W = 180 kJ -> <= 0.87 kg Al-equivalent. Only the Eurolite NSF-250 (3 min, 1000-1080 W) is in that range among the 1 kW machines.
5. Peak from stored heat (CALCULATION, ASSUMPTION fluid 2.3 kJ/ml from 2.2): 25 ml in 30 s = 57 kJ; the heater adds 30 kJ at 1000 W; the remaining ~27 kJ must come from stored heat, i.e. about 38 K of droop on 0.8 kg of aluminium (27 kJ / (0.9 x 0.8)). That bounds ZAD-PRF-04 against the warm-up mass in item 4.
6. Weight and price positioning. 1000 W-class DMX machines weigh 6.3-8.9 kg (Eurolite 6.4, Antari 6.6-7.75, Hurricane 6.3-8.9) and cost USD 233-380; pro machines 8.6-25 kg and GBP 532 / USD 1,750. Antari's compact no-DMX Z-800 MK3 is USD 196; our EUR 229 incl. VAT with DMX and wireless remote sits below every DMX machine in the set (cheapest DMX: ADJ Jett USD 233, 700 W, 9 min).
7. Remote and DMX. Included wireless remotes are one-way RF with short range on budget machines (Eurolite 5 m); Antari's optional Z-50 claims 50 m; Chauvet ships a 4.5 m wired timer remote. No source read describes two-way status or per-machine pairing on a competitor remote. DMX is mostly 1 channel with 3-pin XLR (Antari: 0-128 off, 129-255 maximum output; Chauvet 1 ch); more channels only at ADJ (1-7) and Eurolite (8); RDM only on the Antari Z-1000X MK3 (Thomann text).
8. Vendors admit spitting and give a short cleaning interval. Antari manual: "All fog machines may sputter small amounts of fog occasionally during operation and for a minute or so after being turned off"; cleaning "after every 40 hours of continuous operation" with 80 % distilled water / 20 % acetic acid [S5]. Our targets (zero droplets, 100 h cleaning interval) are differentiators, not table stakes.

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2. Fog fluids

2.1 Composition from safety data sheets (SDS)

Types: Q = quick / extra-quick dissipating, S = standard, L = long-hang / dense / heavy. "Mass fraction" is as printed; a range or "<" is quoted as printed.

Reading the table (CALCULATION/observation):

• Glycol families in use: propylene glycol (+ glycerol), PG + triethylene glycol (+ butylene glycol at Rosco), dipropylene glycol (Le Maitre Standard, Look), diethylene glycol (Chauvet EU). The wetted-material list of the machine must therefore tolerate PG, DPG, DEG, TEG, glycerol, 1,3-butylene glycol, pH 4-8 and water at up to ~65 mass %.
• Mass fractions by fluid type are published only by Antari (FLC 33/2/65; FLG group 38-41/6-8/52-57) and Le Maitre (Global Deluxe only). Martin, Look and Rosco give no per-type split. Long-hang/dense fluids are the ones with the lower water content (Le Maitre Global Deluxe < 40 % water vs 52-65 % at Antari).
• Flash points are 95-103 C (Antari FLG group, Martin) up to > 177 C (Look 2012); auto-ignition is given only by Look 2012 (> 370 C). A heat exchanger at 250 C is above every published flash point, which is normal for flash-vaporising machines; the reservoir and pump side stay near ambient.
• Fluid safety classification: Chauvet FFDJ5 SDS gives DEG with Acute Tox. 4 (H302) in the component table, while the mixture is "not classified". ANSI E1.5 lists DEG as an allowed component (2.4).

2.2 Energy per ml of fluid (CALCULATION, supports ZAD-PRF-02/-04)

Method: heat 1 ml from 20 C liquid to vapour at 1 atm and exit temperature T_exit; water from CoolProp (IAPWS, ddpy); glycol values are ASSUMPTIONS from handbook data (PG: cp 2.5 kJ/kgK, vapourisation 830 kJ/kg at 188 C, vapour cp 1.9 kJ/kgK; DPG: bp 232 C, 520 kJ/kg; TEG: bp 285 C, 470 kJ/kg; glycerol: bp 290 C, 880 kJ/kg; mixture density from the SDS column above). Glycols with boiling point above T_exit are counted as heated only (lower bound). Script run 2026-10-30 with /opt/dd/venv/bin/python -I.

Consequences: 22 ml/min of a PG/glycerol fluid needs 780-880 W of net heat into the fluid; the dense TEG-type fluid needs ~625-670 W. With a 1000 W rated input including pump and electronics (ZAD-PWR-02) the required net transfer efficiency for the standard fluid is about 84-88 %. The energy per ml is dominated by the latent heat of the water share, so a fluid with less water lowers the heater demand but also yields less visible fog per ml.

2.3 Published heat-exchanger temperature or temperature window

Result: no manufacturer publishes a heat-exchanger temperature per fluid type in the manuals read (Antari, Look Viper NT, Smoke Factory, Rosco, Froggys Fog). The Martin/JEM and MDG machine manuals were not read. A search for decomposition-temperature literature was not completed (the web-search tool returned an error for that query).

Design window used in the concept (ASSUMPTION, reason: Antari's published 250 C average, PG boiling point 188 C, TEG 285 C, E1.5 clause 3.3 on thermal-degradation products): set-point adjustable 220-280 C by fluid type with a 250 C default (PG/glycerol fluids 230-250 C; DPG/TEG-rich dense fluids 260-280 C), hard limit by the manual-reset cut-out at ~300-330 C (3.4). This must be verified in the prototype by checking fog quality and by an aldehyde screening or supplier statement; it is not a measured value.

2.4 ANSI E1.5 - scope summary (SOURCE [S36], read in full)

• Title and edition: ANSI E1.5-2009 (R2014), "Entertainment Technology - Theatrical Fog Made With Aqueous Solutions Of Di- And Trihydric Alcohols" (ESTA, reaffirmed by ANSI 9 June 2014; first edition approved 12 May 2003; later reaffirmations 2018 per a copy on looksolutionsusa.com, not read in full).
• Scope: the composition of the fog (not of the machine): theatrical fogs and mists unlikely to harm healthy performers, technicians or audience aged 18-64; limited to fogs made from water plus one or more dihydric or trihydric alcohols ("glycol fogs"). No limits are implied for other populations. Intended for theatres, arenas and places of assembly; may serve as guidance elsewhere with a similar population.
• Allowed components (3.1): triethylene glycol 112-27-6; monopropylene glycol 57-55-6; diethylene glycol 111-46-6; dipropylene glycol (25265-71-8, 106-62-7, 110-98-5, 108-61-2); 1,2-butylene glycol 584-03-2; 1,3-butylene glycol 107-88-0; glycerin 56-81-5. Fogs made with other chemicals (colouring agents, scents, bactericides) are "not necessarily considered a health risk" but "do not meet the requirements of this standard".
• Concentrations in the air breathed (3.2): total alcohols <= 10 mg/m3 TWA (8 h); never above 40 mg/m3 peak; glycerin-only fog never above 50 mg/m3.
• Decomposition products (3.3): formaldehyde, acrolein, acetaldehyde and other thermal degradation products must stay below the lowest permissible level of the governing occupational-health authority (OSHA, HSE). Contaminants such as acetone and ethylene glycol (3.4) likewise.
• Not covered: fluid mass fractions, machine temperature, fluid dissipation behaviour, output measurement. Compliance is a manufacturer claim; ESTA states it does not certify. For our design E1.5 constrains which fluids may be approved (3.1 list; no ethylene glycol, no unlisted additives) and requires that the heat exchanger does not raise thermal-degradation products, which supports the temperature limit in 2.3.

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3. Key purchasable components - specifications and prices

Price cell notation: a / b / c = unit price at qty 1 / 100 / 1000. "n/a" = not available. All LCSC rows: lcsc Cxxxx, JLCPCB list price in USD, DB row data 2026-10-29 (0.7 d old); stock as of that read. Product URL pattern https://www.lcsc.com/product-detail/Cxxxx.html (page returned HTTP 200 for C6280124).

3.1 Peristaltic stepper metering pumps (candidates for 1-60 ml/min)

Notes

• Pressure gap (SOURCE + ASSUMPTION): none of the Kamoer documents read states a maximum outlet pressure; every flow table is for water at atmospheric pressure. Suitability for 1-2 bar back-pressure (coil plus nozzle) is therefore UNVERIFIED (ASSUMPTION: needs a bench test of flow vs back-pressure and of tube life with fluid at up to 40-60 C pump-housing temperature). "KPP" and "KHS" data sheets and Boxer / Williamson data were not found in this pass.
• Operating temperature: Kamoer working environment 0-40 C, humidity < 80 % [S43]; ZAD-REL-02 asks for full performance at 40 C ambient (target) next to a 250 C exchanger, so the pump needs thermal isolation.
• Noise (CALCULATION, free-field, ASSUMPTION that the quoted dB are SPL at the stated distance): KAS-ST 53 dB at 0.5 m -> ~47 dB at 1 m (53 - 20 log10(2)); KFS and KCS "<= 60 dB" with distance not stated -> up to 54 dB at 1 m if measured at 0.5 m. Against ZAD-UX-01 (<= 45 dB(A) at 1 m target, 55 threshold), the pump alone may use up most of the budget.
• Flow resolution / ripple (CALCULATION): KPHM100 stepper: 65 ml/min at 250 rpm = 0.26 ml per revolution, so 2 ml/min (ZAD-PRF-05 target) = 7.7 rpm = 26 full steps/s on a 200-step motor, easily resolved with TMC2209 microstepping. With 3 rollers there are 3 roller transitions per revolution, i.e. one every 2.6 s at 2 ml/min (87 microlitres between transitions); ripple at that rate is a design item for the fluid path, not a limit of the driver. Flow is independent of mains voltage (24 V from the PSU), so one pump serves the EU and the US variant.
• Price at 100/1000: n/a (no quote requests allowed). For the cost model use ASSUMPTION: 70 % of the qty-1 price at 100 pcs and 45-60 % at 1000 pcs for OEM purchase (no source; to be replaced by a quote in the next phase).
• Life vs requirement (CALCULATION): BPT tube life >= 1000 h (at 420 rpm, no pressure) vs ZAD-REL-01 target >= 2000 h: the tube is a consumable at about 1000 h unless run at lower rpm ("the slower the pump head speed, the longer the pump tube life", datasheet note); motor life 6000 h for the stepper versions, 800 h for the brushed NKP (rules out NKP for a 1000-2000 h life).

3.2 Alternatives: vibratory pumps and micro gear pumps

Notes

• ULKA noise level (dB), life (hours) and flow at 1-2 bar are not published in the pages read (n/a). The espresso types EX5/EP5 are rated 2/1 or 1/1 min on/off at 15 bar; at 22 ml/min they would run at about 3.4 % of free flow (22 / 650, CALCULATION), thermal duty then likely below rating (ASSUMPTION; verify). The fog-machine family NME/NMEHP is a better fit on paper (16-27 W, free flow 53-200 cc/min, pressure 2.5-4.7 bar, NMEHP listed with ED 100 % continuous duty) but its flow at 1-2 bar back-pressure is not given; the artsound.gr prices are from an archive snapshot of 2025-06-30 (live page blocked) and must be re-checked. A 120 V / 60 Hz NME-family version was not found (only the 220 V / 60 Hz NMEHP Type 1).
• Vibratory pumps pulse with the line frequency ("pulse in synchronization with AC line frequency", 1st-line.com snippet) and 120 V and 230 V versions are different parts, so the EU and US variants need different pumps and metering depends on mains voltage and back-pressure: ZAD-PRF-06 (<= 5 %) needs a flow sensor or voltage compensation. Price advantage vs stepper peristaltic: EUR 25-35 vs ~PLN 150 (about 4.5-5x lower, CALCULATION on nominal figures, no FX).
• Gear pumps: nominal 20 ml/min is the bottom of their speed range (internal leakage, poor accuracy); prices of USD 100-330 for real metering gear pumps are well above the cost target (no datasheet read).

3.3 Cast aluminium fog-machine heaters / heat exchangers, 900-1500 W

Method: spare-part shops and Chinese/Indian marketplace listings, read 2026-10-30. Alibaba and AliExpress item pages returned no text; rows from eBay, RS and some shops are search snippets and are marked. Only the Topright listing shows a price ladder; no fog-specific heater listing had a 1 / 100 / 1000 ladder. Row A1 was re-read by me; the other rows were read by a research sub-agent with verbatim quotes kept in the working notes (treat as SOURCE, re-check before ordering).

Observations (CALCULATION, ASSUMPTION that block mass is mostly aluminium):

• Commercial 900-1500 W blocks weigh 0.45 kg (AUCD 900 W), 0.86-1.08 kg (1200-1500 W rods), 1.23 kg (Eurolite 1000 W) and 4.10 kg (Antari 1200 W). Energy to heat the block alone to 250 C: 0.45 kg -> 93 kJ (103 s at 900 W); 1.23 kg -> 255 kJ (255 s = 4.3 min at 1000 W) using cp_Al 0.90 kJ/kgK and dT 230 K. Eurolite states ~3 min for the whole NSF-250, so either the effective heat capacity is lower than all-aluminium or READY is declared below 250 C (ASSUMPTION: the thermoswitch of that machine is rated 215 C).
• Prices: spare-part retail EUR 35-240 for fog heater blocks; marketplace 110 V heating cores PLN 107-154; OEM die-cast aluminium heater blocks with an internal stainless pipe are listed at USD 5-15 per piece at MOQ 500 (EP Trend) without coil, tolerance or pressure data; a cast-in tubular heater plate is USD 5-7. The OEM price of a finished exchanger with cast-in coil is therefore a quote item (n/a here).
• The AUCD listings state a "working temp 200-250 C" for cast mineral-insulated cores (110 V). No listing gave coil bore, wall thickness or pressure rating.

3.4 Manual-reset thermal cut-outs (~300-330 C) and thermal links (>= 240 C)

Pages read 2026-10-30 by a research sub-agent (verbatim quotes kept; treat as SOURCE and re-check before ordering). Thermik, Sensata/Klixon, Honeywell and Ubukata: no manual-reset part above 250 C was found (n/a); the Thermik series 01 high-temperature range (205-250 C) is auto-reset (search snippet).

B1 - manual-reset limiters near 300-330 C

B2 - one-shot thermal links, Tf >= 240 C, >= 10 A / 250 V AC

Notes (SOURCE from the datasheets/pages above unless tagged):

• A manual-reset limiter at 300-330 C is a capillary-type part: bimetal-disc manual-reset parts in the VDE-rated datasheets read stop at +250 C (Microtherm TK32); a Calco datasheet gives ceramic-body KSD301 manual-reset units a maximum operating temperature of 220 C (sub-agent reading, not re-read). The only >= 300 C items found are capillary limiters (JUMO, E.G.O.) at retail prices of AUD 92-114, USD 139 and AED 1,764 at qty 1 (not converted here). Even the cheapest of these (E.G.O. 55.13452.010) is of the same order as the whole EUR 60 unit-cost target at retail (ASSUMPTION: rough FX), so for the cost model a 300-330 C manual-reset cut-out is a quote item with high single-source risk (ASSUMPTION: the OEM volume price is unknown; none was found).
• Competitors protect at much lower temperatures: the Eurolite NSF-250 heater spare list names a "Thermoswitch 215 C NSF-250 DMX" (Steinigke machine page, read by the sub-agent) and Eurolite lists a "Thermoswitch 190 C N-19" for EUR 4.33 incl. GR VAT (artsound.gr archive snapshot 2025-06-30, read by me). That puts the competitor cut-out 85-140 K below the 300-330 C concept value; either the control point is cooler than the exchanger core or the concept limit is far above what competitors need (ASSUMPTION; to be settled by the FMEA).
• A Tf 240 C link opens below a 300-330 C limiter. Th of the 240 C links is 190-200 C, so the link must sit at a cooler spot than the limiter bulb or the operating window must stay below about 200 C at the link.
• Cantherm DF260S and DF280S exist but are PSE-only in the datasheet table; the RS "Limitor SF240E" page returned 403 (price and approvals n/a). Thermodisc Microtemp G4 tops out at Tf 257 C.

LCSC/JLCPCB DB check (SOURCE lcsc query 2026-10-30): KSD301-type bimetal thermostats in the DB top out at 150-160 C (C48392785 KSD301T-160B5, USD 0.5388 / 0.3112 / 0.2686); KSD9700 series 50-125 C; no manual-reset >= 250 C thermostat and no thermal fuse with Tf >= 240 C could be identified in the DB (the "SETfuse" family lists 200 C as a maximum-exposure figure, not a trip temperature).

3.5 PT1000 probes rated >= 400 C

Read 2026-10-30 by a research sub-agent unless noted; the LCSC DB holds no sheathed high-temperature PT1000 probe.

Notes: Heraeus, IST, JUMO, Omega and Sensing Devices sheathed probes: n/a (IST and Heraeus only appeared as chip elements). Class A above +300 C is questionable (Therma's own table), expect Class B at 400 C unless a wire-wound element is confirmed. The lead and connector must also survive the exchanger temperature: Evosensors' M12 plastic body is rated 90 C and Process Parameters' glass-fibre lead 0...350 C. Verified probes cost EUR 38.50-77 at qty 1 (EUR 54-59 at 10-25+ for the Therma probe); the cost model needs an OEM quote (the Made-in-China USD 5-65 line is an unverified supplier claim).

3.6 Electronics from the offline LCSC/JLCPCB database

DMX and XLR cost arithmetic (CALCULATION from the table): three-chip isolated DMX interface SP3485 + CA-IS3722HS + B0505S-1WR3 = 0.1435 + 0.1949 + 0.3996 = USD 0.74 at 1000 pcs; ADM2587E alone USD 6.31 (8.5x). XLR set 3-pin in + thru + 5-pin in + thru (NC3MAH + NC3FAH1 + NC5MAH + NC5FAH) = 1.1923 + 1.3184 + 3.6569 + 3.616 = USD 9.78 at 1000 pcs (3-pin pair only 2.51; 5-pin pair only 7.27).

Link-budget check for the radio (CALCULATION, supports ZAD-FUN-03; ASSUMPTION TX +9 dBm at the antenna and 0 dBi antennas): free-space loss at 50 m and 2.44 GHz = 20 log10(50) + 20 log10(2.44e9) - 147.55 = 74.2 dB; with BLE 125 kbps sensitivity -104 dBm the margin is 9 + 104 - 74.2 = 38.8 dB for fading, body loss and enclosure; at 0 dBm TX it is 29.8 dB. The module grant allows mobile and fixed use at 20 cm; a hand-held remote worn near the body needs its own RF-exposure evaluation (ASSUMPTION from the grant text).

3.7 Mains-side parts: relay isolation, inlets, cord sets, connector prices at other suppliers

Pages read 2026-10-30 by a research sub-agent (verbatim quotes kept; treat as SOURCE, re-check before ordering). Blocked to scripts: Mouser, Newark/Farnell/CPC, RS, Future, Full Compass (their figures below are search snippets where marked). Alibaba pages returned no text; Made-in-China listings are supplier claims.

A. Mean Well IRM-30-24, non-LCSC prices

Spec notes: Mean Well catalog and series page: "No load power consumption < 0.075~0.3 W" (catalog) and "< 0.075 W ~ 0.1 W" (series page), "Isolation Class II", "3 years warranty", "Pass LPS" [catalog https://www.meanwell.com/Upload/PDF/catalog.pdf]. The 2026-04-03 spec sheet says working temperature -30...+85 C and 85-305 Vac; TME, DigiKey, TRC and Alimentatorishop still show -30...+70 C and (TME, Alimentatorishop) 85-264 Vac - an older revision; the derating curve is graphical and was not read. No distributor ladder at 100 / 1000 from a readable non-LCSC shop was found; the TME cache hints at about -12 % from 1 to 100.

B. XLR panel connectors, other suppliers (USD)

Not usable as equivalents: Hicon HI-X3CF (cable plug), Switchcraft D3F/D3M (solder-cup panel type), no Amphenol "AC3MMH/AC3FF" part found. Neutrik publishes no list prices. Generic Chinese panel XLRs at USD 0.10-0.90 (MOQ 100-1000) are search snippets only and none claims the NC3FAH footprint.

C. IEC C14 inlet with fuse holder and double-pole switch

Notes: The generic module's dielectric values (2,000 V / 1,500 V) are below Schurter's (> 2.5 kVAC / > 3 kVAC) and its approval claims are unverified. Schurter DD11 plus a fuse drawer is USD 15-22 at qty 1-100 at distributors vs USD 3.2-4.0 for the generic module (CALCULATION from the table); relative to the EUR 60 unit-cost target the inlet module is therefore a 6-35 % item depending on source.

D. Detachable mains cord sets, 3 m

No verified qty-100/1000 ladder exists for a 3 m, 3 x 1.0 mm2, VDE-certified Schuko cord or a 3 m, 18 AWG SVT, UL-listed cord; those cells are n/a. The bulk certification fields are mostly ISO9001/CCC, i.e. no VDE or UL file number was shown; ask for them before ordering.

E. 16 A PCB relays - reinforced-insulation statements (datasheets)

Note: the plain HF115F/024-1HS3A in the LCSC DB (C2976789) is not the "-I" version and no reinforced-insulation statement was read for it; use C2827473 (JQX-115F-I/024-1HS3A, low stock 12) or order HF115F-I via TME/Hongfa channels. Hongfa publishes creepage 10 mm but no clearance value; Finder 40.61 and Omron G2RL state reinforced insulation with 8 mm clearance and creepage in an EN 61810-1 style table.

3.8 Compact price table for the cost model

One line per part; unit prices at qty 1 / 100 / 1000 in the stated currency (no FX applied); "n/a" = no price at that quantity was found. Label SOURCE = read on the page/DB shown; ASSUMPTION = no source, rule given in the note under the table. LCSC rows are JLCPCB list prices (DB row data 2026-10-29), URL pattern https://www.lcsc.com/product-detail/Cxxxx.html.

Notes to the price table

• (a) Kamoer: no volume price was available. ASSUMPTION for the cost model only: 100 pcs = 70 % of the qty-1 price, 1000 pcs = 45-60 % (typical OEM tiers; no source; replace by a quote in the next phase).
• Rows 1-2 and 14-15: the Amazon.com prices exclude shipping/import to Poland (PLN 51.46 and PLN 67.14); not included.
• Rows 5-6: the live artsound.gr page is blocked; the figures are an archive.org snapshot of 2025-06-30, about 16 months old.
• Not priced (no source found): fog-heater block with cast-in coil from an OEM; a 300-330 C manual-reset limiter at OEM volume; high-temperature PT1000 at OEM volume; wireless-remote parts; PCB, passives, enclosure, fuse drawer for the DD11.

Cost hot spots (CALCULATION from the USD qty-1000 column; passives, PCB, enclosure, pump, heater, sensor, cords and remote excluded): IRM-30-24 8.1555 + ESP32-C3-MINI-1-N4 2.0438 + TMC2209 1.6377 + BTA16 0.5061 + MOC3063 0.1253 + relay 1.3347 + OLED 3.2426 + encoder 1.3446 + SP3485 0.1435 + ISO7721DR 0.3914 + B0505S 0.3996 + four Neutrik XLR 9.7836 + generic inlet 3.80 = USD 32.91. The four XLR connectors (9.78) and the PSU (8.16) are the two largest lines; the OLED (3.24) is next. Dropping the 3-pin pair (2.51) or the 5-pin pair (7.27) changes the total by that amount (ZAD-FUN-01 target needs both).

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4. Gaps and what to do next

• Peristaltic pump back-pressure rating (1-2 bar), Kamoer KPP/KHS/KCS Mini pressure data and any Boxer/Williamson data: not found; bench test plus a supplier question in the next phase (no company was contacted in this run).
• ULKA/CEME noise (dB), life (h) and flow-vs-pressure at 1-2 bar: not found (CEME datasheet "Family pump EFM" exists per a search snippet; not read).
• Heat-exchanger temperature per fluid type: not published by any manufacturer read; the 220-280 C window is an ASSUMPTION; MDG, Martin/JEM and Le Maitre machine manuals were not read.
• Competitors: Martin/JEM ZR33, Le Maitre, Rosco fog machines, Showtec not tabulated (no verified live source); no competitor RDM/remote-direction data beyond the table; two street prices (BeamZ, Hurricane 1800 Flex at 399.99 retailers) are search snippets.
• Datasheets not read (marked n/a above): Alps EC11, Chipanalog CA-IS3722, EVISUN B0505S, ADM2587E, BTA16 clone, HS OLED.
• Volume prices (100 / 1000) for Kamoer and ULKA pumps: no source; ASSUMPTIONs flagged in the price table.

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5. Sources

Competitor benchmark

• [S1] Chauvet DJ Hurricane 1301 page, https://www.chauvetdj.com/products/hurricane-1301/ (read 2026-10-30, via fetch tool)
• [S2] Chauvet DJ Hurricane 1800 Flex page, https://www.chauvetdj.com/products/hurricane-1800-flex/ (read 2026-10-30, via fetch tool)
• [S3] Hurricane 1800 Flex User Manual Rev. 3, https://www.chauvetdj.com/wp-content/uploads/2015/12/Hurricane_1800_Flex_UM_Rev3.pdf
• [S4] iDJNow listing, https://www.idjnow.com/chauvet-dj-hurricane-1800-flex-dmx-controllable-fog-machine.html (USD 379.99, 2026-10-30)
• [S5] Antari Z-Series II manual (Z-800 II, Z-1000 II, Z-1020), https://www.antari.com/usermanual/Z/Z-1000II/Z-1000II.pdf
• [S6] Antari Z-1000 III manual, https://www.antari.com/usermanual/Z/Z-1000III/Z-1000III.pdf
• [S7] Antari Z-1200 II / Z-1500 II / Z-3000 II manual, https://www.antari.com/usermanual/Z/Z-3000II/Z-3000II.pdf
• [S8] Thomann US, Antari Z-1000X MK3, https://www.thomannmusic.com/antari_z_1000x_mk3.htm (USD 322, 2026-10-30)
• [S9] Thomann US, Antari Z-800 MK3, https://www.thomannmusic.com/antari_z_800_mk3.htm (USD 196, 2026-10-30)
• [S10] ADJ Fog Fury Jett user manual (rev 03/16/2022), https://d295jznhem2tn9.cloudfront.net/ItemRelatedFiles/8747/ADJ%20Fog%20Fury%20Jett%20-%20User%20Manual%202022-03-16.pdf
• [S11] Thomann US, ADJ Fog Fury Jett, https://www.thomannmusic.com/adj_fog_fury_jett.htm (USD 233, 2026-10-30)
• [S12] Thomann US, Eurolite NSF-250 LED hybrid spray fogger, https://www.thomannmusic.com/eurolite_nsf_250_led_hybrid_spray_fog.htm (USD 242, 2026-10-30)
• [S13] Steinigke, Eurolite set NSF-250 + fluid 5 l, https://www.steinigke.com/mpn20000081-eurolite-set-nsf-250-+-smoke-fluid-dsa-5l.html (EUR 319.00 excl. VAT, 2026-10-30)
• [S14] Thomann UK, Cameo Instant Fog 1700 T Pro, https://www.thomann.co.uk/cameo_instant_fog_1700_t_pro.htm (GBP 532 incl. VAT, 2026-10-30; fetch of the thomann.de/gb URL was served from thomann.co.uk); EUR 629.90 / USD 593 from search snippets of thomann.de and thomannmusic.com
• [S15] Look Solutions Viper NT information sheet, https://www.looksolutions.com/uploads/pdf/en_fr/info_viper.nt_e.pdf
• [S16] Look Solutions Viper NT operating manual, https://www.looksolutions.com/uploads/pdf/en_fr/bed_vipernt_1e.pdf
• [S17] Look Solutions USA machines price list, https://looksolutionsusa.com/product-category/machines/ (Viper NT USD 1,750.00, Viper S 650 W USD 1,375.00, 2026-10-30)
• [S18] beamZ S700LED product page, https://www.beamzlighting.com/product/s700led-smoke-machine-with-ice-effect/
• [S19] bol.com listing https://www.bol.com/nl/nl/p/rookmachine-beamz-s700-rookmachine-700w-incl-400ml-rookvloeistof/9200000021937443/ and https://www.fritz-events.nl/beamz-s700-rookmachine-700w.html (prices from search snippets, pages not read)
• [S60] Martin JEM relocation notice, https://www.martin.com/en-us/product-details/jem-zr33-hi-mass (redirects to https://www.martin.com/resource/jem-products-have-moved.html)

Fluids and standards

• [S21] Antari SDS FLG/FLP/FLY/FLW/FLM/SFL (updated 1 Sept 2026), https://www.antari.com/SDS/FLY/FLY.pdf
• [S22] Antari FLC SDS (28-Mar-2017), https://prostage.no/media/multicase/documents/pdf%20antari/antari%20flc%20safety%20data%20sheet.pdf
• [S23] Antari FLC MSDS rev 1.0 (26-Aug-2013), http://cdb.s3.amazonaws.com/ItemRelatedFiles/9898/antari_flc_fog_fluid_msds.pdf
• [S24] Antari FLG-5 SDS (older), https://partydj.be/PDF-files/Handleidingen/Special-Effects/Antari/FLG-5-safety-data-sheet.pdf
• [S25] Chauvet FFDJ5 SDS (13-Mar-2025), https://www.chauvetdj.com/wp-content/uploads/2024/11/SDS-FOG-FLUID-CHAUVET-FFDJ5-EN.pdf
• [S26] Chauvet FJU SDS (2014), https://www.chauvetdj.com/wp-content/uploads/2015/12/Chauvet-Fog-Fluid-FJU_MSDS_V2_2014.pdf
• [S27] Look Solutions fluid SDS (1-Jan-2021), https://looksolutionsusa.com/wp-content/uploads/2021/02/MSDS-SDS-fluid-2021.pdf
• [S28] Look Solutions fluid MSDS (4-Jan-2012), https://shop.bmisupply.com/Resources/en/ItemDocuments/190UN3151/Look.Solutions.MSDS.pdf
• [S29] Martin Effect Fluids SDS 111N (7-Feb-2025), https://martin.com/km/site_elements/safety-data-sheet-martin-effect-fluids-8c45948f-11fe-4b29-8b47-a0a7af885465
• [S30] Le Maitre Global Deluxe SDS, https://lemaitreltd.com/products/smoke-fog-haze/smoke-fog-haze-fluids/global-deluxe-smoke-fluid/global-deluxe-fluid-safety-data-sheet/
• [S31] Le Maitre Standard SDS, https://lemaitreltd.com/products/smoke-fog-haze/smoke-fog-haze-fluids/standard-smoke-fog-fluid/standard-smoke-fluid-safety-data-sheet/
• [S32] Le Maitre Quick/Extra Quick SDS, https://lemaitreltd.com/products/smoke-fog-haze/smoke-fog-haze-fluids/quick-extra-quick-dissipating-smoke-fog-fluids/quick-extra-quick-fluid-safety-data-sheet/
• [S33] Le Maitre Low Smoke Fluid SDS, https://lemaitreltd.com/products/smoke-fog-haze/smoke-fog-haze-fluids/low-smoke-fluid/low-smoke-safety-data-sheet/
• [S34] Rosco Fog Fluid SDS (06/30/22), https://us.rosco.com/sites/default/files/content/resource/2023-08/Rosco_Fog_Fluid_SDS_063022_V1.pdf
• [S35] Rosco Fog Fluid MSDS (1-Jun-2001), https://www.smokemachines.net/data/rosco/fogfluid.pdf
• [S36] ANSI E1.5-2009 (R2014), https://tsp.esta.org/tsp/documents/docs/ESTA_E1-5_2009_R2014.pdf
• [S37] Smoke Factory Spock manual, https://smoke-factory.de/pdf/betriebsanleitung_spock.pdf
• [S38] Rosco V-Hazer manual, https://www.rosco.com/sites/default/files/content/resource/2016-08/V-Hazer_Manual.pdf

Components

• [S40] Kamoer KPHM100 data sheet (summary page), https://pdf.directindustry.com/pdf/kamoer-fluid-tech-shanghai-co-ltd/kamoer-kphm100-peristaltic-pump-data-sheet/242598-1016662.html
• [S41] Kamoer KAS-ST data sheet, https://pdf.directindustry.com/pdf/kamoer-fluid-tech-shanghai-co-ltd/kas-st-peristaltic-pump-data-sheet/242598-1017432.html
• [S42] Kamoer KFS technical parameters, https://kamoer.com/us/product/params.html?id=1001 ; Kamoer product centre (KCS Mini, KHS2), https://www.kamoer.com/us/product/index.html (search snippet)
• [S43] Kamoer KCP-C technical parameters, http://kamoer.com/us/product/params.html?id=4004
• [S44] Kamoer NKP product manual Edition A/8 (via search snippet), https://m.media-amazon.com/images/I/81sFtvb8fNL.pdf
• [S45] Amazon.com Kamoer KPHM100-STB10, https://www.amazon.com/peristaltic-Stepper-KPHM100-Service-high-Precision/dp/B0B99ZH9C1 (PLN 150.08, 2026-10-30)
• [S46] Amazon.com Kamoer KCS, https://www.amazon.com/min-135ml-peristaltic-Stepper-Adjustable-high-Precision/dp/B0D1R26JR7 (PLN 350.72, 2026-10-30)
• [S47] Amazon.com NKP page showing Kamoer NKP 12 V at PLN 39.42, https://www.amazon.com/5-pack-Kamoer-Peristaltic-Metering-Straight/dp/B0FQCKJQBY
• [S48] Hydronics Depot, ULKA EX5-230V, https://hydronicsdepotinc.com/products/ulka-ex5-230v (PLN 137.00, 2026-10-30)
• [S49] Search-snippet sources for ULKA EP5/EX5 120 V, Chinese fog pumps and gear pumps: https://hydronicsdepotinc.com/products/ulka-ep5-220v , https://hydronicsdepotinc.com/products/ulka-ex5-120v , https://www.kanencoffee.com/store/p/ulka-ex5-vibratory-pump , https://www.artsound.gr/product-category/spare-parts/pumps-heaters/ , https://etco.pk/etco-product/smoke-pump-48w/ , https://sbldjlight.com/product/smoke-pump-48w-rs-1349-smoke-machine/ , https://m.topsflo.com/micro-gear-pump/mg200xk-dc24wi.html , https://m.made-in-china.com/wholesale/micro-gear-pump-price.html
• [S50] Mean Well IRM-30 spec sheet (2026-04-03), https://www.meanwell.com/Upload/PDF/IRM-30/IRM-30-SPEC.PDF
• [S51] IRM-30 datasheet hosted by LCSC (older revision), https://datasheet.lcsc.com/datasheet/pdf/e6bad2cbf94674276a6f3f11e0733a1c.pdf?productCode=C6280124
• [S52] ESP32-C3-MINI-1 datasheet, https://www.espressif.com/sites/default/files/documentation/esp32-c3-mini-1_datasheet_en.pdf
• [S53] ESP32-C3-MINI-1 FCC grant, https://documentation.espressif.com/ESP32-C3-MINI-1%20FCC%20Certification.pdf
• [S54] ESP32-C3-MINI-1 CE (RED) EU-type examination certificate, https://documentation.espressif.com/ESP32-C3-MINI-1-CE%20Certification.pdf
• [S55] ST BTA16 datasheet hosted by LCSC, https://datasheet.lcsc.com/datasheet/pdf/b87c093223292e26510f02f0a3dbe9ba.pdf?productCode=C9100
• [S56] TI ISO772x datasheet, https://www.ti.com/lit/ds/symlink/iso7721.pdf
• Offline parts DB: lcsc CLI over /opt/dd/parts/cache.sqlite3 (JLCPCB list prices, USD), usage per /opt/dd/PARTS.md; LCSC web ladder via https://wmsc.lcsc.com/ftps/wm/product/detail?productCode=Cxxxx for C6280124, C2838502, C2150710.
• [S57] Hydronics Depot ULKA EX5-120V, https://hydronicsdepotinc.com/products/ulka-ex5-120v (PLN 112.00, 120 V / 60 Hz / 41 W, 650 cc/min, 15 bar, ON/OFF 1/1 min, 2026-10-30)
• [S58] artsound.gr "Fog Parts Pumps - Heaters" list, archive.org snapshot of 2025-06-30 (the live site was blocked), https://web.archive.org/web/20250630061653id_/https://www.artsound.gr/product-category/spare-parts/pumps-heaters/ (ULKA NME4/NMEHP/EP-8/EP-77/EP-5/EX-5, JXJD 40DCB, Eurolite pump and "Thermoswitch 190 C N-19" EUR 4.33)
• Sections 3.3, 3.4, 3.5, 3.7 and price-table rows 7-15 and 31-34: every URL is given in the tables; the pages were read on 2026-10-30 by two research sub-agents working from my brief (public web only, read-only, no files written, forbidden site excluded). I re-read the Steinigke page of row A1 and confirmed that the Digi-Key page of row B2-1 loads; other rows rely on the sub-agents' verbatim quotes and should be re-checked before ordering.
• Unverified-by-me search snippets are marked "search snippet" in the tables (BeamZ prices, Hurricane 1800 Flex retailer prices at USD 399.99, Cameo EUR/USD prices, Look Full Compass price, ULKA 120 V retail prices, Chinese pump and gear-pump prices, E.G.O. 55.32555.800 on eBay, FuehlerSysteme).

ZAD-1 compact fog machine: concept alternatives, decision and rationale

Tier: concept. Numbers are labelled SOURCE / CALCULATION / SIMULATION / ASSUMPTION. Calculated values come from estimates/concept_estimates.py (results in estimates/concept_estimates.results.json) and ../09-bom-cost/cost_model.py. Nothing has been built or measured: all physical tests are NOT RUN.

1. What drives the concept

1. Energy per ml sets the continuous output. Vaporising standard water-glycol fog fluid from 20 °C needs about 2.42 kJ/ml (CALCULATION from thermo property data, reference fluid STD = 70 % water, 25 % propylene glycol, 5 % triethylene glycol (ASSUMPTION); quick-dissipating fluid 2.62 kJ/ml, dense fluid 2.23 kJ/ml). The 22 ml/min target (ZAD-PRF-02) therefore needs about 890 W of net heat in the fluid, and the ≤ 1000 W rated input (ZAD-PWR-02) leaves almost no room. Continuous output is fixed by net heater power minus losses. Neither a larger block nor a stronger pump can raise it.
2. Thermal mass trades warm-up against the burst. Warm-up (ZAD-PRF-01) grows linearly with the heat capacity C of the exchanger; the 30-s burst (ZAD-PRF-04) grows only with C × allowed droop. Table 1 shows the trade-off (SIMULATION, STD fluid, 230 V).
3. Reheat pauses are a control problem, not a power problem. Budget machines interlock the pump with an on/off thermostat, so they stop for 20-60 s. If pump flow is always matched to the available heat, the output never stops; it only derates to the continuous rate (ZAD-PRF-03).
4. Spitting comes from liquid reaching the outlet: the block below the vaporisation temperature, pulsating flow, siphoning or drain-down after stop, and condensate in the nozzle (ZAD-PRF-07). The fluid path and the controller must remove each cause.
5. Price: unit cost target €60 (threshold €85) at 1,000 units, retail €229 incl. VAT, with DMX, RDM, a two-way remote, ≤ 3 kg and ≤ 45 dB(A).

Table 1: heat capacity trade-off (SIMULATION, tradeoff_C* in the results file)

With the assumed spit-free droop (block 265 → 235 °C for STD fluid) even C = 1100 J/K does not reach the 25 ml burst target (23.7 ml), and it already misses the 3-min warm-up target (4.67 min). We choose C ≈ 656 J/K. This meets the warm-up target with margin at 230 V (2.78 min; 2.92 min with the heater at −5 % tolerance) and passes the burst threshold (19.7 ml vs 12 ml). The burst target is not met; see §5.

2. System concept alternatives

Weighted evaluation. Weights are the summed priorities of the requirements each criterion represents; scores run from 1 (poor) to 5 (best) and are engineering judgement (ASSUMPTION) based on the estimates above.

3. Sub-system choices (morphological matrix)

4. Decision

Concept B is selected: heat-balance controlled cast exchanger with a stepper peristaltic metering pump, with the sub-system choices of §3. The architecture is described in architecture.md, the block diagram is block-diagram.svg, and the key numbers are in key-estimates.md.

Rationale in one line per requirement group:

• Output (ZAD-PRF-01..-07): concept B is the only alternative that meets warm-up, continuous rate and the no-pause rule together within 1000 W. The positive-displacement pump makes the low end (≤ 2 ml/min) and stability (≤ 5 %) a matter of motor speed, not of mains voltage or back-pressure.
• Power, noise, mass (ZAD-PWR-, ZAD-UX-, ZAD-WGT-01): 1000 W rated, ≈ 37 W ready-hold, ≈ 0.25 W standby, ≈ 39 dB(A), ≈ 2.7 kg (CALCULATION).
• Safety and compliance (ZAD-SAF-, ZAD-CRT-): electromechanical protection independent of firmware, Class I with an earthed metal housing, and pre-certified radio modules. This is the simplest route through EN 60335-1, RED and FCC/NRTL (regulatory-route.md).
• Cost (ZAD-CST-*): ≈ €81 at 1,000 units (CALCULATION from ASSUMPTION prices). This is above the €60 target and within the €85 threshold. Positive margin in all channels at €229.

5. What this decision gives up, and the open decisions

concept_estimates.py - results

Generated by ddpy concept_estimates.py. Inputs labelled SOURCE/ASSUMPTION, outputs CALCULATION/SIMULATION.

ZAD-1 key estimates (concept tier)

Scripts, all re-runnable offline with the toolchain Python (ddpy <script> from its folder):

• estimates/concept_estimates.py → estimates/concept_estimates.results.json (145 values) and estimates/concept_estimates.summary.md (the full table with inputs, labels and notes).
• ../09-bom-cost/cost_model.py → ../09-bom-cost/cost.json, cost_model.results.json, cost.md, concept-bom.csv.

Labels: inputs are SOURCE or ASSUMPTION; outputs are CALCULATION (closed form) or SIMULATION (lumped transient model). There are no MEASUREMENTS. The estimates are about ±10-20 % accurate. The largest uncertainties are the spit-free temperature window per fluid, the insulation conductivity, the pump noise and the part prices.

1. Fluid energy (basis of every output figure)

Method: latent heat at 20 °C plus ideal-gas heat capacity integrated to the exit temperature (setpoint − 20 K). Property correlations are from the thermo package; mixing enthalpy is neglected (a few J/g).

Cross-check with real fluids (SOURCE: SDS data in benchmark-fluids-components.md §2). Branded fluids contain more glycol than our STD assumption: Antari FLC (quick) has 33 % PG + 2 % glycerol (65 % water), the Antari FLG family 52-57 % water, JEM 5-40 % glycols. Their energy need is 1.7-2.4 kJ/ml (CALCULATION in that document). Our STD assumption (70 % water, 2.42 kJ/ml) therefore sits at the energy-hungry end, so the output figures are conservative for most branded fluids. QD (85 % water) stands for extra-quick fluids.

Temperature windows: no fluid maker publishes one. Antari states an average operating temperature of 250 °C (SOURCE, benchmark §2.3), and the research note suggests 220-280 °C. Our STD setpoint of 270 °C is on the hot side. If the fluid test allows 250 °C for STD fluid, warm-up drops to about 2.55 min (as the QD setting) and losses by about 3 W (CALCULATION, same model).

2. Performance (STD fluid unless stated)

3. Thermal, noise, mechanics

4. Cost and price (EUR excl. VAT unless stated; ../09-bom-cost/cost.md)

5. Sensitivities worth knowing

• Heater tolerance −5 %: warm-up +0.14 min, continuous −1.2 ml/min (still above 22).
• Low mains (−10 %): heater −19 %, continuous −20 %, warm-up +24 %. The controller derates; it never pauses.
• Fluid energy +10 % (heavier water content than assumed): continuous −9 % (23.6 → 21.5 ml/min, SIMULATION); the block stays above T_min.
• Heat capacity (table in concept-alternatives-and-decision.md §1): +100 J/K adds ≈ 0.4 min of warm-up and ≈ 1 ml of burst.
• Spit-free droop: each extra 10 K of allowed droop adds ≈ 2.7 ml to the 30-s burst (CALCULATION: 656 J/K × 10 K / 2416 J/ml). The fluid test decides this.

6. Cost-down options toward the €60 target (not yet in the baseline)

Together ≈ €8-10, i.e. ≈ €71-73 at 1,000. That still misses the €60 target. Reaching it would need a cheaper remote or display concept, or a higher batch. Risk in the other direction: a catalogue-price pump (€16-21) would push the unit cost above the €85 threshold (REPORT §6, risk 9).

ZAD-1 regulatory route: EU, US/Canada and ESTA/ANSI (concept stage)

Manager disposition (concept baseline, 2026-10-30):

• D6 (3-pin XLR): the baseline keeps 5-pin and 3-pin XLR in and thru (ZAD-FUN-01 target, DJ market). Conformance to ANSI E1.11 is claimed for the DMX protocol, the electrical interface and the 5-pin ports only. The 3-pin ports are a documented convenience deviation from the E1.11 connector clause; the spec sheet will say so. Fallback: 5-pin only plus adapters (saves about €2.3 per unit), if a customer or a retailer requires full E1.11 conformance.
• D7 (remote): route R1 is adopted (the remote keeps the ESP32-C3-MINI-1 and gets its own FCC ID change and C2PC plus ISED). The one-off cost model carries €34,800 (lean plan of §4) + €2,800 (R1) = €37,600 for certification.
• D1-D5, D8 and D9 are adopted as written.

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0. Decisions at a glance

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1. European Union (ZAD-CRT-01)

1.1 Applicable legal acts

1.2 Harmonised standards and test plan

OJ status was checked in the Commission summary lists:

• LVD list generated 4 Nov 2024 [S2], plus the later amending decisions up to (EU) 2025/1488 [S1][S3].
• EMC list generated 19 Sep 2022 [S5]. No amending decision after (EU) 2022/910 is listed by the Commission or by nlfnorm.cz [S4][S6].
• RED list "generated 7 September 2026" [S8].
• RoHS list [S9].

Under the RED, presumption of conformity comes only from standards cited under the RED (EN 300 328, EN 301 489-17, EN 18031). The LVD- and EMCD-cited standards below are applied as technical specifications under Module A (RED Art. 17(2)). This is permitted for Art. 3(1)(a)/(b).

Every test below has status NOT RUN. All costs and durations are ASSUMPTION unless marked otherwise. Cost IDs (C#) refer to §4.

1.3 EN 60335-1 alone, or a Part 2 by analogy?

What real fog machines declare (research by document; tags as found):

Result: every document found uses EN 60335-1 alone, often with EN 62233. None cites EN 60335-2-15, -2-98 or -2-101. No fog-machine DoC citing EN 300 328 or EN 301 489 was found; the radio-remote models do not publish their lists.

Decision: use Part 1 alone.

• EN 60335-2-15 covers appliances for heating liquids (kettles, boilers). A fog machine vaporises the fluid; it does not heat a liquid for use.
• EN 60335-2-98 covers humidifiers.
• EN 60335-2-101 covers vaporizers for insecticides and fragrances.
• Claiming any of them "by analogy" would bring in requirements that do not fit, and would not add presumption.

The gaps in Part 1 are covered by the risk assessment and by engineering checks:

• Overfill/spill of the tank (cl. 15).
• Dry run with an empty tank.
• Hot-liquid ejection (ZAD-PRF-07).
• Tilted operation (ZAD-FUN-08, ZAD-SAF-05).
• Aldehyde emissions (E1.29).

Safety item for the risk assessment (raise in the clause 19 review):

• Published auto-ignition temperatures of some E1.5-permitted glycols are close to or below the block temperatures:
  • diethylene glycol 224 °C;
  • dipropylene glycol 310 °C (one supplier gives 350 °C);
  • propylene glycol 371 °C (SOURCE [S84]).
• ZAD-1 runs at 250-290 °C, and the cut-out is at about 320 °C.
• Water-based fog is water-rich, and the fluid is inside a closed coil. However, the nozzle surface in a fault (block at the cut-out temperature) must be shown not to ignite the plume.
• Conservative choices:
  • (a) Verify in a clause 19 fault test with the worst-case approved fluid.
  • (b) Exclude DEG-containing fluids from the approved list.
  • (c) Consider a cut-out ≤ 300 °C if (a) fails.

1.4 Clause 19, protective electronic circuits (PEC) and Annex R

• Protection chain:
  1. MCU PID + zero-cross triac (functional control).
  2. Hardware over-temperature comparator + external watchdog, which drop the series mains relay.
  3. Manual-reset bimetal cut-out, about 320 °C (EN 60730-2-9, non-self-resetting).
  4. One-shot thermal link (EN 60691) on the block.
• EN 60335-1 tests that decide it:
  • 19.4: heating appliance at the clause 11 conditions, with every control that limits temperature during clause 11 short-circuited, in turn.
  • 19.11.2: fault conditions in electronic circuits (component shorts/opens, triac short, MCU outputs stuck).
• Design rule: in every clause 19 case, the clause 19 limits must be met with layers 1 and 2 disabled, so that layers 3 and 4 carry the safety alone. Then the comparator/relay/watchdog is not relied on and is not a PEC.
  • Consequence 1: the elevated EMC immunity tests of 19.11.4 do not apply.
  • Consequence 2: no Annex R software evaluation.
  • Ask the lab to run each fault with the electronic layers disabled, and record this in the report.
• Additional checks:
  • The cut-out must have the cycle endurance required by EN 60335-1 cl. 24.1.4 for non-self-resetting cut-outs (value from the purchased standard).
  • Standard organic thermal links are rarely rated above about 240 °C (ASSUMPTION). Place the link where its rating and the fault temperature match, or use a certified high-temperature link.
  • Pump on while heater fails: safe (the fluid cools the block). Pump off while heater stuck on: the cut-out operates.
  • Reset must need a deliberate action (tool or hidden button).
• If a PEC were needed (e.g. the cut-out could not hold the limits on its own):
  • The PEC must keep a safe state during the EN 60335-1 cl. 19.11.4 immunity tests: ESD, radiated and conducted RF, fast transients, surges, and voltage dips/interruptions, at the levels given in the standard.
  • If the PEC uses software, it must be software class B to Annex R, with the Table R.1 fault/error controls: CPU registers, program counter, interrupts, clock, invariable memory (CRC), variable memory (RAM test), addressing, internal data paths, external communication, timing, I/O and A/D.
  • Typical impact: +3-6 weeks and EUR 3,000-8,000 extra lab cost (ASSUMPTION), plus firmware effort. This is avoided by design.

1.5 Draft EU Declaration of Conformity (ZAD-1)

EU DECLARATION OF CONFORMITY                       No. <ZAD-DoC-001>, revision <A>
(DRAFT – not valid until signed after all test reports PASS)

1. Radio equipment: Fog generator ZAD-1, variant ZAD-1-EU (220-240 V~ 50/60 Hz, 1000 W),
   supplied with wireless remote ZAD-1R.
   Serial numbers: <ZAD1E-YYWW-000001> to <ZAD1E-YYWW-00xxxx>
   Firmware: <x.y.z> (and later versions that do not affect compliance)
2. Manufacturer: <legal name>, <street, postcode, city, country>, <e-mail>, <website>
   [Authorised representative: <name, address> or "not applicable"]
3. This declaration of conformity is issued under the sole responsibility of the manufacturer.
4. Object of the declaration: compact fog machine for water-based fog fluids conforming to
   ANSI E1.5; 2.4 GHz Bluetooth LE radio (module Espressif ESP32-C3-MINI-1);
   DMX512-A/RDM interface. [photo]
5. The object of the declaration described above is in conformity with the relevant Union
   harmonisation legislation:
   - Directive 2014/53/EU (radio equipment)
   - Directive 2011/65/EU as amended by Commission Delegated Directive (EU) 2015/863 (RoHS)
   - Commission Regulation (EU) 2023/826 (off mode, standby and networked standby)
6. References to the harmonised standards used, or to other technical specifications:
   Art. 3(1)(a): EN 60335-1:2012+AC:2014+A11:2014+A13:2017+A1:2019+A14:2019+A2:2019+A15:2021
                 (clause 20.2 complemented per Implementing Decision (EU) 2025/1457);
                 EN 62233:2008+AC:2008; EN 62479:2010
   Art. 3(1)(b): ETSI EN 301 489-1 V2.2.3 (2019-11); ETSI EN 301 489-17 V3.3.1;
                 EN IEC 55014-1:2021; EN IEC 55014-2:2021; EN 61000-3-2:2014; EN 61000-3-3:2013
                 [final editions as tested]
   Art. 3(2):    ETSI EN 300 328 V2.2.2 (2019-07)
   RoHS:         EN IEC 63000:2018
   (EU) 2023/826: EN 50564:2011
7. Notified body: not applicable (Module A, Annex II of Directive 2014/53/EU).
8. Accessories and components, including software: wireless remote ZAD-1R (own EU DoC
   No. <ZAD-DoC-002>); detachable mains cord H05VV-F 3G1.0 mm², CEE 7/7 to IEC 60320 C13,
   3 m; firmware <x.y.z>.
9. Additional information: —
   Signed for and on behalf of: <company>
   <place>, <date>          <name, function>          <signature>

ZAD-1R gets its own DoC with the same structure. Its standards:

• EN 300 328 V2.2.2
• EN 301 489-1 V2.2.3 / -17 V3.3.1
• EN IEC 62368-1 (edition as tested)
• EN 62479:2010
• EN IEC 63000:2018

It lists the RED and RoHS only. Its batteries carry the battery maker's own DoC.

Simplified DoC for the manuals (RED Annex VII): "Hereby, <manufacturer> declares that the radio equipment type ZAD-1 [ZAD-1R] is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: <URL>."

1.6 EU markings and instructions (ZAD-SAF-08)

• Rating plate (ZAD-1-EU), per EN 60335-1 cl. 7 and RED Art. 10(6)-(7):
  • manufacturer name/trade mark and postal address;
  • model ZAD-1;
  • serial/batch number;
  • "220-240 V~ 50/60 Hz 1000 W";
  • CE mark (≥ 5 mm);
  • WEEE bin with bar (EN 50419:2022).
• Fuse marking at the fuse holder: "T6.3AH250V".
• Hot-surface symbol IEC 60417-5041 at the nozzle (ZAD-SAF-03).
• ZAD-1R: CE mark, model, batch number, polarity marks; the bin symbol on the cells or packaging (Batteries Reg. Art. 13(4)).
• Instructions (RED Art. 10(8) and EN 60335-1 cl. 7.12), in each MS language:
  • simplified DoC;
  • frequency band 2400-2483.5 MHz and max RF power;
  • children/reduced-capability statement per the EN 60335-1 EN-specific wording;
  • cleaning;
  • fuse replacement;
  • E1.14 content (§3);
  • warnings on smoke detectors and fire alarms, ventilation, slippery residue, minimum distances to people and flammables (value from the clause 11 and nozzle-plume test, ASSUMPTION pending test), hot surfaces, approved fluids only (E1.5), exposure guidance (E1.5: ≤ 10 mg/m³ 8-h average, ≤ 40 mg/m³ peak, SOURCE [S53]), and an asthma notice;
  • power-management/auto-off information ((EU) 2023/826);
  • battery removal ((EU) 2023/1542);
  • WEEE take-back.
• Online listings: the GPSR Art. 19 data set (row 9 of §1.1).

1.7 Technical file outline (RED Annex V + RoHS + Ecodesign + GPSR + PPWR)

1. General description, variants (EU/US), photos (external, internal, labels), firmware versions affecting compliance.
2. Conceptual design and manufacturing drawings: schematics, PCB layouts (insulation barrier and creepage map), BOM with certified components and certificates (inlet/fuse holder/switch, cord sets, cut-out, thermal link, relay, optotriac, PSU, wiring, PCB laminate UL 94/GWFI data).
3. Descriptions needed to understand 1 and 2: operation, safety concept (§1.4), FMEA (ZAD-SAF-01).
4. Risk assessment:
   • RED essential requirements;
   • EN ISO 12100-style analysis (fog, chemical, thermal, mechanical, tilt);
   • machinery classification note (§1.1 row 14);
   • DR 2022/30 / CRA scope assessment (§1.1 rows 11-12);
   • GPSR non-harmonised aspects.
5. List of standards applied (§1.2), with a justification wherever a non-OJ edition or a non-cited standard was used.
6. Test reports: S1-S12, S15, pre-compliance logs, flicker calculation (S7), RF exposure assessment (S3), radio module reports and Espressif integration guidance.
7. RoHS file per EN IEC 63000 (supplier declarations, material data, XRF/lab results). REACH/SCIP/POPs/Prop 65 evidence.
8. Ecodesign 2023/826 file: measured off/standby/networked standby, power-management settings, website information.
9. Copies of the EU DoCs (ZAD-1, ZAD-1R), the simplified DoC, user manual, labels and packaging artwork.
10. Production control: EN 50106 EOL test procedure and limits (ZAD-MFG-03), serial-number scheme, change control (any firmware change touching RF or safety triggers a re-assessment).
11. Batteries (supplier DoC, registration numbers) and WEEE/packaging registrations. PPWR packaging technical documentation and packaging DoC (Art. 39).
12. From 11 Dec 2027: CRA technical documentation (Annex VII of the CRA), SBOM, vulnerability-handling process.
13. Retention: 10 years after the last unit is placed on the market (RED Art. 10(3)).

---

2. United States and Canada (ZAD-CRT-02)

2.1 FCC (47 CFR)

2.2 ISED Canada

2.3 NRTL safety listing (US OSHA NRTL + Canadian SCC-accredited certification)

Why it is needed:

• In Canada, electrical products must be certified by an SCC-accredited body before sale and use (CE Code Part I Rule 2-024 and provincial rules; SECONDARY [S80]).
• In the US, workplace buyers (schools, churches, bars, theatres) need "approved" (NRTL-listed) equipment under OSHA rules, and venues, insurers and retailers ask for it.

Research: which standards real fog-machine listings use

Standards status:

• ANSI E1.29-2009 (R2024) is the ESTA product-safety standard for theatrical fog generators. It is built on UL 998: cl. 2.1 says the UL 998 humidifier requirements "shall be used to evaluate the theatrical fog generators", with the fog-specific changes of cl. 2.2 [S55].
• E1.29 is not on OSHA's list of appropriate test standards. UL 499, UL 998 and UL 60335-1 are [S60]. An NRTL therefore lists to UL 998 or UL 499, not to E1.29 alone.
• Current editions:
  • UL 998, 6th ed. (2020, revised 5 Jul 2022) = CSA C22.2 No. 104:20 (R2025), binational [S64];
  • UL 499, Ed. 14 (2014), revised 17 Nov 2025 [S61];
  • CSA C22.2 No. 64:19 (R2024), 8th ed. (the CSA store may show it as withdrawn: edition to be confirmed) [S63];
  • CSA C22.2 No. 88:19 (R2024) (industrial heating equipment) [S62].

Chosen route: ANSI/UL 998 (6th ed.) / CSA C22.2 No. 104:20 (R2025), with the ANSI E1.29-2009 (R2024) cl. 2.2 modifications applied. Mark: cETLus, cULus or cMETus. Reasons:

1. It is binational: one document and one evaluation cover the US and Canada.
2. E1.29, the industry's own fog-generator safety standard, tells evaluators to use exactly this base, so the entertainment market will recognise it.
3. It is on the OSHA list.
4. There is precedent (JEM).
5. It brings in the fog-specific tests (aldehydes, microbial, fluid effects on components, no knot as strain relief).

Fallbacks:

• UL 499 + CSA C22.2 No. 64 (Chauvet Professional/MET precedent), if the NRTL finds the humidifier scope unsuitable.
• UL 60335-1 + CSA C22.2 No. 60335-1, which could reuse the EN 60335-1 data. However, no Part 2 fits, so the NRTL must accept Part 1 alone. Ask before choosing.

Get a written scope agreement from the NRTL before sample submission.

Main NRTL tests (typical for UL 998/E1.29 programmes; final list from the NRTL quotation; status NOT RUN):

• input power and current at 120 V;
• normal temperature test at continuous fogging;
• leakage current at 1.06 × rated voltage (ZAD target ≤ 0.25 mA);
• dielectric voltage-withstand;
• humidity conditioning, then leakage and dielectric again;
• abnormal operation: dry tank, pump stalled, blocked nozzle, control shorted, triac shorted, relay welded;
• overflow/spillage and tip-over/tilt with fluid;
• cord strain relief and push-back (no knot, E1.29);
• stability and hanging bracket;
• grounding continuity;
• marking permanence;
• component and material review (UL-recognised inlet, fuse holder, switch, fuse, cut-out, thermal link, relay, optotriac, PSU to UL 62368-1, wiring, PCB laminate);
• E1.29 extras: fog fluid evaluated wherever UL 998 asks about fluid effects; formaldehyde/acrolein/acetaldehyde air sampling (C12); microbial test or waiver; French markings (E1.29 Annex B); manual per E1.14.

Cost and timeline:

• Listing project (construction review, tests, report): C18, EUR 6,000-14,000 (exp. 8,000). ASSUMPTION; the secondary estimate is USD 7-9k for the first year [S85].
• Initial production inspection: EUR 1,600 + travel (Intertek ETL 2026 rate card, Swedish entity, SOURCE [S81]), giving C19 exp. EUR 2,000.
• Recurring: certification fee EUR 310 per quarter + follow-up inspection EUR 920 per quarter + travel (SOURCE [S81]). That is EUR 4,920 per year + travel (CALCULATION 4 × (310 + 920)), not counted as one-off.
• Duration: 8-14 weeks from complete samples and documents to listing (ASSUMPTION). The IPI happens at the start of mass production, before the first marked shipment. After that, quarterly unannounced follow-up inspections at the Guangdong factory.

2.4 Other US/Canada points

2.5 US/Canada markings and manual statements

• Rating label (ZAD-1-US):
  • name, model, serial;
  • "120 V~ 60 Hz 1000 W 8.3 A" (rating per baseline; heater 980 W at 120 V draws 8.17 A, CALCULATION);
  • NRTL mark with control number;
  • "Contains FCC ID: 2AC7Z-ESPC3MINI1" and "Contains IC: 21098-ESPC3MINI1";
  • §15.19 statement;
  • "CAN ICES-003(B)/NMB-003(B)";
  • fuse "T10A 250V";
  • cautionary markings per UL 998/E1.29 in English and French (hot surface, use only approved fluid, disconnect before filling/servicing);
  • Prop 65 warning if adopted (§2.4).
• Manual:
  • §15.21 and §15.105(b) texts;
  • §2.1077 compliance information with the US responsible party;
  • RSS-Gen notice in English and French;
  • E1.14 inclusions (§3).

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3. ESTA/ANSI entertainment standards (ZAD-CRT-03)

The current designations below are from ESTA's published-documents list [S50]. Texts were read from ESTA PDFs [S51]-[S55]. ANSI E1.20-2025 was confirmed from the listing only; its text was not read.

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4. One-off certification cost and timeline (ZAD-CST-04, certification share)

Base case:

• EU tests at an ILAC/CNAS-accredited lab of an international group in Guangdong, close to the contract manufacturer.
• FCC/ISED tests at an FCC-recognised lab in an MRA economy (§2.1).
• One NRTL with a China office.

All figures are EUR excl. VAT, ASSUMPTION unless marked. Every test is NOT RUN.

Recurring costs (not one-off):

• NRTL: EUR 4,920 per year + travel (SOURCE-based CALCULATION, §2.3).
• WEEE/battery/packaging EPR fees and authorised-representative fees: about EUR 1,000-3,000 per year (ASSUMPTION).
• US agent fee (ASSUMPTION).

Timeline (T0 = DVT samples frozen, built with production-intent parts):

Critical path: NRTL, about 16 weeks from DVT freeze (ASSUMPTION).

Effect on ZAD-CST-04 (CALCULATION):

• The target is ≤ EUR 30,000 for tooling + certification. Certification alone is already ≈ EUR 40,600 expected, so the target is not reachable with this scope.
• The threshold is ≤ EUR 60,000. It is reachable only if tooling and other one-offs stay ≤ 60,000 − 40,600 = EUR 19,400.
• cost.md must carry these lines.

How the design keeps certification cost down:

1. Pre-certified radio modules (ESP32-C3-MINI-1, FCC/IC modular): no notified body, no FCC certification for the machine, and reduced EN 300 328 testing.
2. No PEC and no Annex R software class B (§1.4): saves about EUR 3,000-8,000 and 3-6 weeks (ASSUMPTION).
3. Certified PSU module (IRM-30 class: EN 62368-1, EN 60335-1, EN 61558-2-16, UL 62368-1, SOURCE [S15]), plus certified inlet, switch, fuse holder, cut-out, thermal link, relay, optotriac and cords: components are not tested again.
4. One mains design and one PCB for both variants. Only the cord, fuse and label differ, so the EU report covers the platform and the NRTL tests only the 120 V variant.
5. BLE capped below 10 dBm e.i.r.p.: no MU/adaptivity tests (S8).
6. Zero-cross burst firing with a ≥ 10 s period: harmonics and flicker pass by design (S6, S7).
7. No internet, Wi-Fi or app: no EN 18031 assessment until the CRA.
8. Pre-compliance first, so that each accredited test runs once.

Lean variant (≈ EUR 35,000, CALCULATION 40,600 − 2,800 − 1,000 − 2,000 = 34,800):

• remote module with a portable grant (−2,800, C17);
• launch in about 3 MS first (−1,000, C13);
• one lab group for EU + FCC + NRTL tests with a bundle discount (≈ −2,000, ASSUMPTION).

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5. Design measures the hardware team must respect

These rules serve ZAD-SAF-06, ZAD-SAF-08 and ZAD-PWR-04. Values from paywalled standards are tagged; confirm them against the purchased copies.

5.1 Insulation coordination (mains ↔ SELV/DMX/BLE: reinforced insulation, working voltage ≤ 250 V)

• Clearance ≥ 3.0 mm. EN 60335-1 cl. 29.1 Table 16: reinforced insulation uses the next rated-impulse step, 2500 V → 4000 V, giving 3.0 mm (SOURCE [S16][S17]; the standard text is paywalled). Design target ≥ 4.0 mm (ASSUMPTION margin).
• Creepage ≥ 5.0 mm at pollution degree 2, material group IIIa/IIIb (FR-4, CTI 175): 2 × 2.5 mm basic (SOURCE [S16][S17]).
  • Use ≥ 8.0 mm (2 × 4.0 mm, pollution degree 3) wherever fog fluid or condensate can reach: pump bay, tank side, near the outlet. Otherwise seal the electronics compartment from the fluid path; that is the conservative choice.
  • Route a slot under the optotriac and relay barrier.
• Solid insulation, reinforced: ≥ 2 mm, or thin-sheet layers that meet cl. 29.3 (value to be confirmed in the standard).
• Hipot (type test): 3000 V reinforced, 1250 V basic, for 230 V (EN 60335-1 cl. 16.3 Table 7; to be confirmed in the standard).
• Barrier components:
  • PSU with reinforced insulation, 4.2 kVac I/P-O/P (SOURCE [S15]);
  • optotriac rated reinforced (IEC 60747-5-5 / VDE 0884-11 + UL 1577) in a wide package (≥ 8 mm external creepage);
  • relay coil-to-contact reinforced (EN 61810-1);
  • any Y-capacitor across the barrier must be class Y1.
• PT1000 on the earthed block: separation from the heater relies on the heater sheath insulation plus the protective-earthed block. Either confirm this with the lab, or use a sensor sheath rated ≥ 1.5 kV.

5.2 Fire (EN 60335-1 cl. 30; unattended appliance, cl. 30.2.3)

ZAD-1 runs unattended on a timer or under DMX, so cl. 30.2.3 applies.

• Insulating parts supporting connections that carry > 0.2 A, and parts within 3 mm of them, need:
  • GWFI ≥ 850 °C, and
  • GWIT ≥ 775 °C, or a glow-wire test at 750 °C with flames ≤ 2 s (SOURCE [S18][S19]).
• This applies to: the inlet/fuse/switch combination, terminal blocks, relay/triac PCB area, heater/cut-out connectors and cable ties near connections.
• Ball pressure test for parts that support live parts (cl. 30.1).
• Near the 250-290 °C block, use only ceramics, mica, glass-fibre silicone sleeving rated ≥ 300 °C (ASSUMPTION rating), or PFAS-certified PTFE.

5.3 Earthing (EN 60335-1 cl. 27)

• ≤ 0.1 Ω from the C14 earth pin to every accessible metal part and to the heat-exchanger block.
• Test current 25 A: 1.5 × 4.35 A = 6.5 A is below 25 A, so 25 A applies (CALCULATION; rule per cl. 27.5).
• Design target ≤ 0.05 Ω (ASSUMPTION margin).
• Construction:
  • dedicated earth stud (not shared with a fixing screw), crimped ring tag, serrated washer and locknut;
  • star bonding to the block, shroud, housing panels and hanging bracket;
  • green/yellow conductors;
  • the earth conductor breaks last under strain.
• The same limit applies for the NRTL grounding-continuity test. The 100 % EOL test follows EN 50106 (ZAD-MFG-03).

5.4 Leakage budget (ZAD-SAF-06: target ≤ 0.25 mA at 1.06 × rated voltage)

Test voltage: 1.06 × 240 V = 254.4 V for EU; 1.06 × 120 V = 127.2 V for US.

At 127.2 V and 60 Hz the capacitive parts scale by about 0.6 (CALCULATION: 127.2/254.4 × 60/50 = 0.60), so the US variant has more margin. For comparison, the standard limits (EN 60335-1 cl. 13.2/16.2 for Class I portable appliances, 0.75 mA; NRTL typically 0.5 mA for cord-connected appliances) are looser than the ZAD target (values to be confirmed in the standards).

5.5 Components and materials

• Certified components (certificate copies go in the technical file and the NRTL file):
  • C14 inlet + fuse holder + double-pole switch: ENEC/VDE + UL/cUL;
  • fuses: EN 60127-2 / UL 248-14;
  • cut-out: EN 60730-2-9 + UL 873/60730;
  • thermal link: EN 60691 + UL 60691;
  • relay: EN 61810-1 + UL 508;
  • optotriac;
  • PSU;
  • cord sets: HAR H05VV-F with VDE/ENEC plug; US SJT with UL 817 cord set;
  • internal wiring: UL 758 AWM, rated temperature appropriate to location;
  • PCB laminate: UL 796, V-0.
• EU cord: a CEE 7/7 plug covers DE, FR, PL, NL, ES, AT and BE. For IT, DK, CH, UK and IE, plan extra cord variants (ASSUMPTION; market decision).
• Chemicals:
  • lead-free brass;
  • non-phthalate (DINCH/DOTP) SCCP/MCCP-free PVC, or TPE, for cords;
  • PAH-tested feet and knobs;
  • PFAS-free certificates for fluoropolymers;
  • no decaBDE or other brominated flame retardants;
  • supplier declarations for RoHS, REACH (253 SVHC), POPs and Prop 65.

5.6 Markings and instructions (ZAD-SAF-08)

• The EU set is in §1.6, the US/CA set in §2.5, and the E1.14/E1.29 content in §3.
• Hot-surface symbol at the nozzle; the outlet is guarded so IEC 61032 probe B cannot reach it (ZAD-SAF-03).
• "Use only E1.5 water-based fog fluid".
• Smoke-detector and fire-alarm warning.
• Slippery-residue warning.
• Minimum distance to people and flammables (value from test).
• Disconnect before filling or servicing.
• Fuse rating at the holder.
• Language versions: all EU languages of sale, plus EN/FR for Canada.
• Laser-etched or polyester rating label that passes the marking-durability rub test (water + petroleum spirit per EN 60335-1 cl. 7.14; NRTL permanence test).

5.7 Standby and power management (ZAD-PWR-04, (EU) 2023/826)

• Off mode = double-pole mains switch ahead of the PSU: 0 W.
• Standby (heater off, DMX receiver + BLE listening): ≤ 0.5 W design budget. Limits are 0.80 W with display / 2.00 W networked (SOURCE [S20]).
• Turn off the OLED and the RS-485 driver bias where allowed, and keep the RS-485 receiver at low power.
• Idle auto-off: default ON, ≤ 20 min; changing it needs a warning on the display. The setting survives power-off; factory reset restores the default.

5.8 Radio and firmware (RED 3(2), FCC/ISED, CRA)

• Machine: BLE ≤ +5 dBm conducted (≈ 9 dBm e.i.r.p. with the 3.96 dBi antenna, CALCULATION) to stay below 10 dBm e.i.r.p. (EN 300 328) and within the 5 mW FCC grant.
• Remote: ≤ -2 dBm conducted, including tune-up tolerance (FCC 1 mW exemption, ISED 3 mW exemption).
• Power caps are fixed in firmware and not user-adjustable.
• Wi-Fi code is not linked in.
• Secure boot, flash encryption and signed USB updates (CRA).
• Bonded-only BLE.
• DMX loss → output stops ≤ 2 s (ZAD-SAF-07).
• Pump never runs unless READY.

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6. Open points and items not confirmed

1. ZAD-FUN-01 conflict. The target asks for 3-pin XLR DMX ports, which ANSI E1.11-2024 §7.1 does not allow. Recommendation: 5-pin only + adapters. The design team must decide.
2. ZAD-1R radio approval. The ESP32-C3-MINI-1 FCC grant excludes portable use. Choose route R1 (FCC ID change + C2PC, which needs Espressif's authorisation; a business step not taken here) or R2 (a portable-approved module).
3. RSS-247 Issue 4. The module's IC certificate cites Issue 3. Get Espressif's statement on Issue 4 before the Canadian launch.
4. (EU) 2023/826 scope. There is no official ruling on fog machines; ZAD-1 is treated as in scope (conservative). No harmonised measurement standard was confirmed in the OJ (EN 50564:2011 is used).
5. OJ editions. No EMC amending decision after (EU) 2022/910 was found, so EN IEC 55014-1/-2:2021, EN IEC 61000-3-2:2019+A1:2021 and EN 61000-3-3:2013/A1/A2 are treated as not cited. The OJ edition of EN IEC 62368-1 (remote) is to be confirmed. Re-check all lists at DoC signature.
6. Machinery classification: arguable (§1.1 row 14). Get a written lab opinion.
7. NRTL standard: UL 998/CSA C22.2 No. 104 + E1.29 is the chosen route, based on precedent and E1.29. Get the NRTL's written agreement. The CSA C22.2 No. 64 edition and status are to be confirmed (fallback only).
8. FCC Third R&O (29 Oct 2026): the adoption and exact rule text are from press reports (SECONDARY). Re-check before booking FCC tests.
9. Glycol auto-ignition vs block/cut-out temperature (§1.3): a fault test with the worst-case approved fluid is needed. The approved-fluid list may need to exclude DEG.
10. Paywalled standard values (creepage/clearance tables, hipot voltages, leakage limits, cut-out cycles, EN 50106 limits) are quoted from secondary sources or from memory as noted. Confirm them against the purchased standards before the design freeze.
11. Costs: all are ASSUMPTION except the Intertek rate card [S81] and the secondary price points [S82][S83][S85]. Replace them with three written quotes (EU lab, FCC lab, NRTL); requesting quotes is a business step not taken here.
12. Not covered: UK (UKCA/PSTI), Switzerland, Australia and other markets.

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Sources

All accessed 2026-10-30. Official EUR-Lex texts were read through the Publications Office repository (publications.europa.eu/resource/celex/…) where EUR-Lex blocked scripts.

• [S1] European Commission, harmonised standards, Low voltage (LVD): https://single-market-economy.ec.europa.eu/single-market/european-standards/harmonised-standards/low-voltage-lvd_en
• [S2] LVD summary list (generated 4.11.2024), xlsx: https://single-market-economy.ec.europa.eu/document/download/1ef6946b-6bb6-4f18-bacd-7640e47d5da0_en?filename=2014_35_EU_Low_Voltage_Summary%20list%20of%20harmonised%20standards_Generated%20on%204.11.2024.xlsx
• [S3] Commission Implementing Decision (EU) 2025/1457 of 16 July 2025 (EN 60335-1 restriction, cl. 20.2): https://eur-lex.europa.eu/eli/dec_impl/2025/1457/oj (text via http://publications.europa.eu/resource/celex/32025D1457); also checked (EU) 2025/1488 and (EU) 2025/1464
• [S4] European Commission, harmonised standards, EMC: https://single-market-economy.ec.europa.eu/single-market/european-standards/harmonised-standards/electromagnetic-compatibility-emc_en
• [S5] EMC summary list (generated 19.9.2022), xlsx: https://single-market-economy.ec.europa.eu/document/download/0af395ce-e9e0-417c-a7d4-988f5ef3ef7d_en?filename=2014_30_EU_EMC_Summary%20list%20of%20harmonised%20standards_Generated%20on%2019.9.2022.xlsx
• [S6] nlfnorm.cz harmonised-standards database, EN 55014-1:2017 record (amendments of (EU) 2019/1326 up to (EU) 2022/910): https://www.nlfnorm.cz/en/ehn/6661
• [S7] European Commission, harmonised standards, Radio equipment: https://single-market-economy.ec.europa.eu/single-market/european-standards/harmonised-standards/radio-equipment_en
• [S8] RED summary list (file header "Generated 7 September 2026"), xlsx: https://single-market-economy.ec.europa.eu/document/download/1b07bf21-0158-466f-9865-2fcba3bf67d6_en?filename=SummaryListForLegislation_generated%2013.10.2025.xlsx
• [S9] European Commission, harmonised standards, RoHS (Implementing Decision (EU) 2020/659; summary list PDF): https://single-market-economy.ec.europa.eu/single-market/goods/european-standards/harmonised-standards/restriction-use-certain-hazardous-substances-rohs_en and https://single-market-economy.ec.europa.eu/document/download/bce01d75-c495-40db-b422-77aa8599bd74_en
• [S10] ETSI EN 300 328 V2.2.2 (2019-07): https://www.etsi.org/deliver/etsi_en/300300_300399/300328/02.02.02_60/en_300328v020202p.pdf
• [S11] EN IEC 60335-1:2023/FprAB:2026 (iTeh record, Annex ZF): https://standards.iteh.ai/catalog/standards/clc/098e2071-55cd-403c-b4d2-6c6689c4156f/en-iec-60335-1-2023-fprab-2026 ; status summaries: https://www.ibf-solutions.com/en/news-and-knowledge/official-journals/standards-for-the-low-voltage-directive
• [S12] EN 50106:2008: https://standards.iteh.ai/catalog/standards/clc/9b3f6dfc-af46-41a2-8b01-f3a9c5b3eb45/en-50106-2008 ; SIS: https://www.sis.se/en/produkter/domestic-and-commercial-equipment-entertainment-sports/home-economics-in-general/ssen501062/
• [S13] EN IEC 63474:2026 (networked standby measurement): https://standards.iteh.ai/catalog/standards/clc/a0fe4e91-3cde-405a-b70c-22717d1a2832/en-iec-63474-2026
• [S14] IEC 61000-3-3:2013 preview (analytical flicker method, limits): https://cdn.standards.iteh.ai/samples/19367/fbf1fcffc30b43e28407edc627d0d5c9/IEC-61000-3-3-2013.pdf
• [S15] Mean Well IRM-30 series datasheet: https://www.meanwell.com/Upload/PDF/IRM-30/IRM-30-SPEC.PDF
• [S16] DigiKey, "How to meet IEC 60335 power supply requirements…": https://www.digikey.com/en/articles/how-to-meet-iec-60335-power-supply-requirements-for-home-appliances-and-iot-devices
• [S17] MinMax, clearance and creepage in PCB design: https://www.minmaxpower.com/en/resource/clearance-creepage-pcb-design
• [S18] Schurter white paper "Components and IEC 60335-1": https://www.farnell.com/datasheets/1712864.pdf
• [S19] LANXESS, IEC 60335-1 glow-wire requirements: https://techcenter.lanxess.com/scp/emea/en/docguard/TI_2006-011_EN_IEC_60335_Advanced_standard_for_domestic_appliances.pdf?docId=109963
• [S20] Commission Regulation (EU) 2023/826: https://eur-lex.europa.eu/eli/reg/2023/826/oj
• [S21] Commission guidance, off mode / standby / networked standby: https://energy-efficient-products.ec.europa.eu/document/download/62dd1683-63f2-4e02-8a88-f55cb521b9bd_en?filename=Guidance%20document_Lot%2026_Networked%20Standby_clean%20FIN_0.pdf
• [S22] GPSR (EU) 2023/988: https://eur-lex.europa.eu/eli/reg/2023/988/oj
• [S23] Batteries Regulation (EU) 2023/1542: https://eur-lex.europa.eu/eli/reg/2023/1542/oj
• [S24] PPWR (EU) 2025/40: https://eur-lex.europa.eu/eli/reg/2025/40/oj
• [S25] Cyber Resilience Act (EU) 2024/2847: https://eur-lex.europa.eu/eli/reg/2024/2847/oj
• [S26] Commission CRA implementation FAQ: https://digital-strategy.ec.europa.eu/en/library/cyber-resilience-act-implementation-frequently-asked-questions
• [S27] Delegated Regulation (EU) 2026/339 (repeal of 2022/30 from 11 Dec 2027): https://eur-lex.europa.eu/eli/reg_del/2026/339/oj
• [S28] Delegated Regulation (EU) 2022/30: https://eur-lex.europa.eu/eli/reg_del/2022/30/oj
• [S29] RED Guide, version 07.07.2026: https://single-market-economy.ec.europa.eu/document/download/a0c7e4c5-27db-4c59-9c43-a380ed21563f_en?filename=RED%20Guide%20-%20version%2007.07.2026%20-%20with%20COVER.pdf
• [S30] Implementing Decision (EU) 2025/138 (EN 18031-1/-2/-3): https://eur-lex.europa.eu/eli/dec_impl/2025/138/oj
• [S31] ECHA press release, Candidate List update (253 entries; secondary confirmation of count): https://echa.europa.eu/-/echa-adds-two-hazardous-chemicals-to-the-candidate-list-1
• [S32] Regulation (EU) No 1272/2013 (REACH Annex XVII entry 50, PAH): https://eur-lex.europa.eu/eli/reg/2013/1272/oj
• [S33] Regulation (EU) 2018/2005 (entry 51 phthalates): https://eur-lex.europa.eu/eli/reg/2018/2005/oj
• [S34] Directive (EU) 2018/851 (SCIP basis): https://eur-lex.europa.eu/eli/dir/2018/851/oj
• [S35] POPs Regulation (EU) 2019/1021 and amendments (EU) 2023/1608, 2025/718, 2025/1399, 2025/843, 2025/1930, 2025/1482: https://eur-lex.europa.eu/eli/reg/2019/1021/oj
• [S36] Council document ST 13064/26 (MCCP delegated regulation C(2026) 6262): https://data.consilium.europa.eu/doc/document/ST-13064-2026-INIT/en/pdf
• [S37] WEEE Directive 2012/19/EU: https://eur-lex.europa.eu/eli/dir/2012/19/oj
• [S38] Directive (EU) 2024/884 (EN 50419:2022 reference): https://eur-lex.europa.eu/eli/dir/2024/884/oj
• [S39] Product Liability Directive (EU) 2024/2853: https://eur-lex.europa.eu/eli/dir/2024/2853/oj
• [S40] Antari Z-380/Z-390 DoC/EMC report (ASP Technology): https://prostage.no/media/multicase/documents/pdf%20antari/z-390-an_ce%20emc,%20asp_c1.pdf
• [S41] Swefog K1 owner's manual with DoC: https://swefog.com/wp-content/uploads/2018/06/Owners-manual-K1-Rev-2-2021-02-19.pdf
• [S42] Fog, Smoke & Haze Factory Spaceball II DoC (Thomann): https://images.thomann.de/pics/atg/atgdata/document/misc/233340_konformitaetserklaerungspaceball2.pdf
• [S43] JEM ZR series EU DoC (now 404): https://jemprofessional.com/wp-content/uploads/2025/10/JEM-ZR-Series_EU-DoC-EN.pdf ; JEM Hazer Pro: https://jemprofessional.com/jem-hazer-pro/
• [S44] Stairville AF-150 DMX DoC (snippet): https://device.report/m/f281fea42b24219c39d8c9c1f63fb9618118031addde4d13d497f385f9d3ec57.pdf
• [S45] BeamZ manuals: https://www.emimikos.gr/Documents/BEAMZ-S1500-Manual_En.pdf ; https://media.djmania.net/manuales/pdf/Manual_BeamZ_S2000.pdf
• [S46] Rosco Vapour user guide: https://us.rosco.com/sites/default/files/content/resource/2019-01/Vapour_FogMachine_UserGuide_v1_rev3.pdf
• [S47] Eurolite NSF-100: https://www.manualslib.com/manual/1508286/Eurolite-Nsf-100.html ; https://www.steinigke.de/en/mpn51701961-eurolite-nsf-100-led-dmx-hybrid-spray-fogger.html
• [S48] Guide to application of the Machinery Directive 2006/42/EC, edition 2.1: https://www.cencenelec.eu/media/CEN-CENELEC/Areas%20of%20Work/CEN%20sectors/Mechanical%20and%20Machines/Mechanical%20engineering/Doc%20and%20materials/edition-2-1-of-the-md-guide.pdf
• [S49] Safety Gate fog machine alert A12/1693/19 (LVD/EN 60335-1), secondary: https://www.bromley.gov.uk/leaflet/328565/22/680/d
• [S50] ESTA TSP published documents list: https://tsp.esta.org/tsp/documents/published_docs.php
• [S51] ANSI E1.11-2024: https://tsp.esta.org/tsp/documents/docs/ANSI%20E1.11%20-%202024.pdf
• [S52] ANSI E1.27-1-2006 (R2016 copy; current R2021): https://tsp.esta.org/tsp/documents/docs/E1-27-1_2006R2016.pdf
• [S53] ANSI E1.5-2009 (R2014 copy; current R2024): https://tsp.esta.org/tsp/documents/docs/ESTA_E1-5_2009_R2014.pdf ; https://webstore.ansi.org/standards/esta/ansie12009r2024
• [S54] ANSI E1.14-2018 (R2023): https://tsp.esta.org/tsp/documents/docs/ANSI_E1-14_2018_R2023.pdf
• [S55] ANSI E1.29-2009 (R2018 copy; current R2024): https://tsp.esta.org/tsp/documents/docs/ESTA_E1-29_2009_R2018.pdf
• [S56] E1.20-2025 PID changes (secondary, unverified): https://github.com/HakanL/Haukcode.ArtNet/issues/32
• [S57] Chauvet Professional Amhaze Stadium (MET E115095, UL 499, CSA C22.2 No. 64-10): https://www.chauvetprofessional.com/products/amhaze-stadium/
• [S58] Martin JEM Compact Hazer Pro manual (UL 998, CSA C22.2 No. 104-01): https://adn.harmanpro.com/site_elements/resources/7319_1595015927/UM_JEMCompactHazerPro_EN_B_original.pdf
• [S59] Listing marks without standard: https://www.chauvetdj.com/products/hurricane-haze-4d/ ; https://www.chauvetdj.com/products/hurricane-1000/ ; https://ultratecfx.com/wp-content/uploads/2022/04/Radiance-Hazer.pdf ; https://www.mdgfog.com/en/theone ; https://us.rosco.com/en/product/v-hazer ; https://www.adj.com/products/fog-fury-3000 ; https://www.idjnow.com/antari-f-80z-fog-machine.html
• [S60] OSHA NRTL program, list of appropriate test standards: https://www.osha.gov/nationally-recognized-testing-laboratory-program/list-standards
• [S61] UL 499 Ed. 14: https://www.shopulstandards.com/ProductDetail.aspx?UniqueKey=47760 ; Intertek notice: https://www.intertek.com/siteassets/resources/sun/2025/ul-499-sun-rev-11-17-2025-ed-7-31-2028.pdf
• [S62] CSA C22.2 No. 88:19 (R2024): https://www.csagroup.org/store/product/2426855/
• [S63] CSA C22.2 No. 64:19 (R2024): https://www.csagroup.org/store/product/2427107/
• [S64] UL 998 / CSA C22.2 No. 104:20 (binational): https://webstore.ansi.org/standards/csa/csac221042020 ; https://www.csagroup.org/store/product/2427124/ ; https://store.accuristech.com/standards/ul-998?product_id=3046201
• [S65] Espressif, ESP32-C3-MINI-1 FCC grant (FCC ID 2AC7Z-ESPC3MINI1, grant notes): https://documentation.espressif.com/ESP32-C3-MINI-1%20FCC%20Certification.pdf
• [S66] Espressif, ESP32-C3-MINI-1 ISED certificate (IC 21098-ESPC3MINI1): https://www.espressif.com/sites/default/files/ESP32-C3-MINI-1%20IC%20Certification.pdf
• [S67] ESP32-C3-MINI-1 datasheet v2.2: https://documentation.espressif.com/esp32-c3-mini-1_datasheet_en.pdf
• [S68] Precedent FCC ID 2BGE7-P300 (C2PC for portable use), secondary: https://fccid.io/2BGE7-P300
• [S69] FCC KDB 996369: https://apps.fcc.gov/oetcf/kdb/forms/FTSSearchResultPage.cfm?id=44637&switch=P
• [S70] FCC KDB 447498: https://apps.fcc.gov/oetcf/kdb/forms/FTSSearchResultPage.cfm?switch=P&id=20676 ; secondary: https://verkotan.com/2022/changes-in-rf-exposure-guidance/
• [S71] ISED ICES-003 Issue 7: https://ised-isde.canada.ca/site/spectrum-management-telecommunications/en/devices-and-equipment/interference-causing-equipment-standards-ices/ices-003-information-technology-equipment-including-digital-apparatus
• [S72] ISED RSS-247: https://ised-isde.canada.ca/site/spectrum-management-telecommunications/en/devices-and-equipment/radio-equipment-standards/radio-standards-specifications-rss/rss-247-digital-transmission-systems-dtss-frequency-hopping-systems-fhss-and-licence-exempt-local
• [S73] ISED RSS-Gen: https://ised-isde.canada.ca/site/spectrum-management-telecommunications/en/devices-and-equipment/radio-equipment-standards/radio-standards-specifications-rss/rss-gen-general-requirements-compliance-radio-apparatus
• [S74] ISED RSS-102: https://ised-isde.canada.ca/site/spectrum-management-telecommunications/en/devices-and-equipment/radio-equipment-standards/radio-standards-specifications-rss/rss-102-radio-frequency-rf-exposure-compliance-radiocommunication-apparatus-all-frequency-bands
• [S75] eCFR 47 CFR §2.906, §2.948, §2.1077: https://www.ecfr.gov/current/title-47/part-2/section-2.906 ; https://www.ecfr.gov/current/title-47/part-2/section-2.948 ; https://www.ecfr.gov/current/title-47/part-2/section-2.1077
• [S76] FCC draft fact sheet, Third R&O ET Docket 24-136: https://docs.fcc.gov/public/attachments/DOC-425721A1.pdf ; press (secondary): https://law360.com/articles/2544150/fcc-agrees-to-rules-targeting-some-foreign-test-labs ; earlier enforcement: https://docs.fcc.gov/public/attachments/DOC-414863A1.pdf
• [S77] Prop 65, 27 CCR §25603: https://www.law.cornell.edu/regulations/california/27-CCR-25603 ; OEHHA final text: https://oehha.ca.gov/media/downloads/crnr/finalregtext112624approval.pdf
• [S78] 10 CFR 430.2: https://www.ecfr.gov/current/title-10/part-430/section-430.2
• [S79] Competition Bureau Canada, CPLA guide: https://competition-bureau.canada.ca/en/guide-consumer-packaging-and-labelling-act-and-regulations
• [S80] CE Code Rule 2-024 (secondary): https://electricalindustry.ca/latest-articles/standata-2-024-equipment-hv-splice-kits/
• [S81] Intertek ETL certification rates 2026 (Sweden): https://www.intertek.se/siteassets/business-lines/electrical/etl-certification-process/etl-certification-rates-2026_general-information-2025-11-20.pdf
• [S82] FCC Part 15B cost examples (secondary): https://markready.io/learn/fcc-certification-cost ; https://docs.particle.io/hardware/certification/certification/
• [S83] ISTA test prices (secondary, vendor list price): https://smallbusiness.sealedair.com/products/ista-procedure-3-series ; https://www.cdf1.com/ista-testing-a-guide-to-packaging-transit-testing/
• [S84] Auto-ignition temperatures: https://en.wikipedia.org/wiki/Dipropylene_glycol ; https://en.wikipedia.org/wiki/Diethylene_glycol ; https://cameochemicals.noaa.gov/chris/PPG.pdf
• [S85] ETL first-year cost estimate (secondary): https://seller.alibaba.com/blogs/2026/southeast-asia/electrical-products/etl-certification-guide-alibaba-b2b
• [S86] RoHS Directive 2011/65/EU and Delegated Directive (EU) 2015/863: https://eur-lex.europa.eu/eli/dir/2011/65/oj ; https://eur-lex.europa.eu/eli/dir_del/2015/863/oj
• [S87] 47 CFR §1.1307 (RF exposure exemptions; Table 1 to (b)(3)(i)(C)): https://www.ecfr.gov/current/title-47/part-1/section-1.1307